Non-polarity of the PEEK matrix makes it difficult to directly join metal and the carbon-fiber-reinforced-PEEK by friction lap joining. Laser surface texturing is proposed to assist the friction lap joining of the carbon-fiber-reinforced-PEEK, which is a nonpolar thermoplastic matrix, and 6061-T6 aluminum alloy, significantly enhancing the bonding strength of the carbon-fiber-reinforced-PEEK/6061-T6 joints. Results show that the laser surface texturing produces the dual-scale hierarchical structure of micro-pores and nano-particles on 6061-T6 surfaces, thereby changing the wettability of the surfaces. The superhydrophobic surface of 6061-T6 exhibits higher adhesion property with the carbon-fiber-reinforced-PEEK than the hydrophobic surface does. A flawless interface is observed in the joint of the carbon-fiber-reinforced-PEEK and 6061-T6 with the superhydrophobic surface. The micromechanical interlocking caused by micro-pores and nano-particles on 6061-T6 surfaces explains the enhancement of the bonding strength between the carbon-fiber-reinforced-PEEK and 6061-T6.
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