The Influence of Low-Pressure Plasma Treatments on the Lap Shear Strength of Laser-Joined AISI 304 Hybrids with Polypropylene and Polyamide 6.6

This paper investigates if the polar groups induced by a plasma treatment can increase the lap shear strength of laser-joined metal and plastic hybrids. Optimal laser joining parameters for cold-rolled AISI304–polyamide 6.6 and sandblasted AISI304–polypropylene hybrids were developed at 2.85 MPa and 4.22 MPa, respectively. The surface free energy was doubled for all used plasma gases to a value of ca. 80 mN m−1 at 180 s. The plasma-treated samples were joined and tested. The arithmetic means of the plasma-treated hybrids’ lap shear strength with polyamide 6.6 varied slightly, but all measured values were within the range of the untreated samples. Residue on the sheared metal samples indicated covalent bonds between AISI304 and polyamide 6.6. The lap shear strengths of the plasma-treated polypropylene hybrids were significantly reduced between −30.8% and −53.3%, depending on the used plasma gas. This was attributed to the over-aging and development of low-molecular-weight oxidized materials, which led to a weak boundary layer. No residue of polypropylene was found on treated or untreated lap shear samples. No correlation between the surface free energy and lap shear strength could be found.