Study on Bonding Characteristics of Aluminum Alloy Treated by Plasma Electrolytic Oxidation Process and Polymer Resin Bonded by Direct Injection Molding

Aluminum alloy and polymer resin hybrid bonding technology is essential for lightweight mobile phone frames and automotive components. Recently, there has been extensive research on a method of bonding metals and polymer resins by treating the metal surface and then direct injection molding. However, this method requires separate surface treatment of the aluminum alloy after bonding to enhance its corrosion resistance. This paper studies the use of Plasma Electrolytic Oxidation, one of the surface treatment methods for aluminum, to achieve the bonding of aluminum and polymer resin in a single surface treatment step while ensuring high corrosion resistance. We conducted research to investigate optimal conditions by adjusting the process variables of Plasma Electrolytic Oxidation, in order to achieve integration with the polymer resin and measure the bonding strength and corrosion resistance. The surface characteristics of each Plasma Electrolytic Oxidation condition were analyzed using scanning electron microscopy and atomic force microscope equipment, while the bonding strength was measured using universal testing machine equipment. The corrosion characteristics were evaluated by measuring the corrosion resistance in a saltwater solution.