Development of industrial solutions for laser texturing of aluminum surfaces prior to adhesive bonding

Manufacturing processes constantly evolve to match the increasing need for fast and reliable production methods, especially in the automotive industry. The use of lasers for material processing applications is one way to achieve excellent performance and reliability by using a sustainable, cost-effective solution with minimal operational costs. Laser texturing can be used to prepare metallic surfaces prior to bonding, which is a common assembly method. In fact, a good surface preparation is critical for adhesive bonding to ensure the durability of the joint. With laser texturing, the physico-chemical properties of the etched surface can be altered to enhance the joint’s performance.

This study aims to develop fast, repeatable, and versatile industrial solutions for preparing aluminum surfaces before bonding using a high-power fiber laser. Surfaces are laser textured using various parameters and then bonded with well-known adhesives. Bonded joints are subjected to mechanical resistance tests and aging cycles to simulate real-life conditions. The morphology and chemical composition of the treated surfaces are analyzed to demonstrate the increase of rugosity and formation of surface oxides that promote adhesion. A set of laser texturing parameters that can withstand a rigorous aging cycle and is presented.