Effect of aluminum surface treatment on mechanical behavior of Al/CF-PEEK components fabricated through one-step hot stamping

Fiber-metal hybrid structures are important for lightweight vehicles, with widespread applications in aircraft and increasingly in automobiles. The bonding properties between metal and composite layers significantly influence the performance of these hybrid components. In this study, V-shaped Al-CF/PEEK components were fabricated through one-step hot stamping, employing two surface treatments (publishing and anodizing) on the AA6061 alloy. The effect of interface properties on the mechanical behavior and failure mechanisms of hybrid components was then examined through DIC-assisted four-point bending tests and macro/micro morphological analysis. The results indicate that weak bonding at the Al/CFRP interface in the polished specimens led to premature delamination at this interface. This delamination disrupted load distribution and induced more interface failures, ultimately diminishing component performance. Conversely, anodizing strengthened the bond, ensuring effective load transfer during bending, fundamentally altering the failure mode and improving the mechanical properties of the hybrid component.