Atmospheric plasma activation and thin film deposition processes for adhesion improvement and corrosion resistance in the automotive industry

Abstract The latest trends in the automotive industry show a shift towards more lightweight, robust vehicles powered by electric energy. Light weighting can be achieved through the use of carbon‐reinforced composite materials or light metals, such as aluminum, and by using adhesives for bonding instead of rivets and bolts. In this paper, results from the characterization of plasma‐treated polypropylene using water contact angle goniometry, X‐ray photoelectron spectroscopy, and attenuated total reflectance Fourier‐transform infrared spectroscopy are presented, showing the functionalization of the surface with chemical groups originating in the plasma phase. The improved adhesion to a hot melt adhesive is discussed and linked to an industrial headlamp application. Other case studies presented involve the plasma treatment of thermoplastic elastomers for car doors, the surface modification of semi‐trailer panels, and the deposition of plasma‐derived nanocoatings on aluminum substrates to promote corrosion resistance.