The adherend surface topography has a dramatic effect on the durability of structural bonds formed between aluminium and an epoxy adhesive. Systematic changes in the micro-roughness of an aluminium adherend were achieved using an ultra-milling technique to prepare surfaces with topographies ranging from ultra-flat to a sawtooth profile with a base angle of approximately 60° and a peak-to-valley depth of 10 μm. The fracture toughness of double-cantilever beam specimens, stressed in the Mode 1 direction and exposed to a humid environment was found to change by a factor of approximately one hundred as the sawtooth profile angle was increased. These changes in fracture toughness may be accounted for through complex interrelationships between moisture diffusion and interphase mechanical properties, each with a strong dependence on the surface micro-topography.
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Rider et al. (2001) studied this question.
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