Silicone foam, as a damping material, is widely used between metal components in integrative device systems. After long-term service, silicone foam tends to adhere to metal substrates, thus leading to the disassembly difficulty and compromising the system reliability. Owing to the interfacial complexity when the silicone foam and the metal component stick to each other, the underlying adhesion mechanisms still remain unclear. This study aims to elucidate the adhesion mechanism between the silicone foam and the metal substrate using a stainless steel/silicone foam/stainless steel sandwiched structure through accelerated aging and under compressive stress. Multiscale techniques from morphology, spectroscopy and depth profile were applied to study the joint interfacial structures and elucidate the adhesion mechanism between the silicone foam and stainless steel. It was demonstrated that the silicone foam-stainless steel adhesion behavior arose from the synergistic effects of thermo-oxidative aging and compressive stress, which had induced physical and chemical changes of the silicone foam at the interface. Specifically, the interfacial interactions were comprised of covalent bonding (Si−O−Metal), micro-mechanical interlocking, hydrogen bonding, and van der Waals force. Such findings shall provide new insights into the adhesion mechanisms of polymer-metal interfaces and offer practical guidance for the design and reliability assessment of damping materials in engineering applications.
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