Ultra-Improved Interfacial Strength Between Metallic Surface and Polyurethane via Cost-Effective Anodizing Process
Bakhbergen U. Araby S. Tauanov Z. Turdakyn N. Montazami R. Abbassi F. Kalimuldina G.
17 February 2026John Wiley and Sons Inc
Advanced Materials Interfaces
2026#13Issue 4
Interfacial strength at the metal-adhesive joint is a pivotal parameter to define adhesive bond reliability and its overall mechanical performance. This study systematically investigates and optimizes sulfuric acid anodizing (SAA) parameters to promote the interfacial strength between aluminum Al2024 (Al) alloy and polyurethane (PU). Response surface methodology (RSM) was employed for the design of experiments by altering acid concentration, anodizing current, and time. Surface roughness and contact angle were measured to assess the effect of these parameters, while scanning electron and atomic force microscopies were employed to elucidate structure-property relationships. SAA exceptionally enhanced the interfacial strength by increasing the contact area by creating a micro- and nano-porous oxide layer, resulting in a 920% and 15 100% improvement in the single lap shear strength (SLSS) and fracture energy, respectively, after 45 min anodizing. By maximizing SLSS and minimizing cost through time, electric current, and concentration, RSM defined the optimum SAA conditions at 0.4144 M concentration, 1.0907A current, and 5.505 min; experimental measurements validated the optimized outcomes, showing respective increases of 600% and 6700% in SLSS and fracture energy. Also, the failure mode shifted from adhesive to predominantly cohesive mode. Additionally, different machine learning (ML) algorithms were trained using various combinations of anodizing and surface topography features; the most influential parameters were identified while mitigating overfitting despite the limited dataset. Among all tested ML models, support vector regression showed the highest accuracy, achieving a remarkable mean absolute percentage error of ≈11%. The study highlights the effectiveness of SAA to enhance Al/PU interface strength.
interfacial strength , machine learning , RSM , single lap joint , sulfuric acid anodizing
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Department of Mechanical and Aerospace Engineering, Nazarbayev University, Astana, Kazakhstan
Faculty of Chemistry and Chemical Technology, Al-Farabi Kazakh National University, Almaty, Kazakhstan
Ecology Research Institute, Khoja Akhmet Yassawi International Kazakh-Turkish University, Turkestan, Kazakhstan
Department of Mechanical and Aerospace Engineering, University of Missouri, Columbia, MO, United States
College of Engineering and Technology, American University of the Middle East, Kuwait
Department of Mechanical and Aerospace Engineering
Faculty of Chemistry and Chemical Technology
Ecology Research Institute
Department of Mechanical and Aerospace Engineering
College of Engineering and Technology
10 лет помогаем публиковать статьи Международный издатель
Книга Публикация научной статьи Волощук 2026 Book Publication of a scientific article 2026