Bonds mechanical interlocking

Because moisture will break the dispersive interfacial bonds, mechanical interlocking on a micro- or nanoscopic scale is needed between the adhesive/primer and adherend for good... 

He concluded that for aluminium and titanium certain etching or anodization pretreatment processes produce oxide films on the metal surfaces, which because of their porosity and microscopic roughness, mechanically interlock with the polymer forming much stronger bonds than if the surface were smooth . 

In recent years there has been a renewed appreciation of potential beneficial effects of roughness on a macroscale. For example Morris and Shanahan worked with sintered steel substrates bonded with a polyurethane adhesive [61]. They observed much higher fracture energy for joints with sintered steel compared with those with fully dense steel, and ascribed this to the mechanical interlocking of polymer within the pores. Extra energy was required to extend and break these polymer fibrils. 

The surface preparation must enable and promote the formation of bonds across the adherend/primer-adhesive interface. These bonds may be chemical (covalent, acid-base, van der Waals, hydrogen, etc.), physical (mechanical interlocking), diffusional (not likely with adhesive bonding to metals), or some combination of these (Chapters 7-9). 

The scale of the microscopic surface roughness is important to assure good mechanical interlocking and good durability. Although all roughness serves to increase the effective surface area of the adherend and therefore to increase the number of primary and secondary bonds with the adhesive/primer, surfaces with features on the order of tens of nanometers exhibit superior performance to those with features on the order of microns [9,14], Several factors contribute to this difference in performance. The larger-scale features are fewer in number... 

A more recent process, the P2 etch [60], which uses ferric sulfate as an oxidizer in place of sodium dichromate avoids the use of toxic chromates, but still provides a similar oxide surface morphology (Fig. 15) allowing a mechanically interlocked interface and strong bonding [9]. The P2 treatment has wide process parameter windows over a broad range of time-temperature-solution concentration conditions and mechanical testing confirms that P2-prepared surfaces are, at a minimum, equivalent to FPL-prepared specimens and only slightly inferior to PAA-prepared surfaces [61]. 

Overmolding is the process by which two different materials are joined into one assembly without using secondary operations like gluing or welding. In case the materials are chemically compatible, chemical bonds may form between them and so mechanical interlocks are not required. There are two common techniques of overmolding—insert molding and multiple-shot injection molding. 

Cyclization is generally very effective in improving the adhesion of TR and SBR to polyurethane adhesives. Rubbers treated with concentrated sulfuric acid yield a cyclized layer on the surface. This layer is quite brittle, and when flexed develops microcracks, which are believed to help in subsequent bonding by favoring the mechanical interlocking of the adhesive with the mbber. 

Supramolecular chemistry takes into consideration the weak and reversible non-covalent interactions between molecules, which include H-bond-ing, metal coordination, hydrophobic forces, van der Waals forces, n—n interactions, and covers different research fields, for example, molecular recognition, host-guest chemistry, mechanically interlocked and nanochemistry. 

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