Abstract
In this study, the effects of the surface treatment condition on the bonding strength in the ABS resin directly formed on the aluminum alloy and its load mode dependence were investigated. The ABS resin was deposited as a column on the aluminum alloy treated by a laser surface roughening process using the direct-additive-manufacturing method. The tensile test, the tensile fatigue test, the shear test, and shear fatigue test of the direct-additive-manufactured resin/metal joints were performed. The experimental results revealed that appropriate surface roughness by laser roughening process improves the bond strength of the joints. In particular, the bond strength for the optimized surface roughness implemented sufficient strength as a structural member in both loading modes. On the other hand, the fatigue bond strength has a loading mode dependence and was significantly lower than the monotonic bond strength. It was found from the fracture surface observations that cohesive failure of ABS resin was observed on most parts of the fracture surface in the direct-additive- manufactured-resin/metal joints, in contrast, the adhesive failure was observed only at the edge part. Based on the experimental results, the fracture mechanisms were discussed.
