Recent Advances in Aluminum Alloy Surface Treatment Technology and Bonding Properties

Aluminum alloys are widely used in lightweight automotive structures due to their excellent properties. To deeply explore the development of surface bonding technology, aluminum alloy is selected as the object, and current research status of aluminum alloy surface treatment methods is reviewed. The adhesion mechanism during joint preparation, the method of adhesive selection, and the bonding process are summarized. This overview discusses the impact of different surface treatment processes on aluminum alloy joints from two perspectives: substrate characteristics and joint failure modes. It examines how these processes affect surface roughness, surface morphology, surface contact angle, surface free energy, surface chemical composition, and bonding performance. Additionally, it looks ahead to key directions for future research on adhesive joint performance. The results indicate that surface treatment increases the surface roughness of aluminum alloys, reduces the contact angle, and improves surface wettability. Moreover, chemical elements or functional groups that enhance adhesion are introduced on the surface, improving the bonding capability between the adhesive and the substrate. Compared to single‐surface treatment methods, hybrid treatment methods significantly enhance the surface characteristics of aluminum alloys and are expected to become a primary focus for future research on bonded joint performance.