Nanoscale‐Sculptured Al Microparticles as Universal Hierarchical Adhesion Promoters

A combination of properties (e.g., biocompatibility, abrasion resistance, chemical inertness, etc.) from different polymers is desirable in many applications such as in medical and marine fields. However, joining nonstick polymers is still challenging. Herein, a facile and environmentally friendly approach is demonstrated to improve the adhesion between nonstick polymers through mechanical interlocking using a low amount of nanoscale‐sculptured Al microparticles. The hook‐like structures for mechanical interlocking are created on Al microparticles by nanoscale sculpturing, that is, a wet chemical etching process. By the incorporation of nanoscale‐sculptured Al microparticles at a polydimethylsiloxane (PDMS)/polythiourethane (PTU) interface serving as just one demonstrator example, the peeling strength of PDMS from PTU is 30 times higher compared with that without Al microparticles and 4 times higher than that with untreated Al microparticles, respectively. The significant increase in adhesion can be attributed to the penetration of both polymers into the hook‐like structures of nanoscale‐sculptured Al microparticles, forming a tight and strong hierarchical mechanical interlocking.