PhD Defence Atiyeh Adelinia | Aluminium-Thermoplastic Composite Joints by Plasma Electrolytic Oxidation Coating

Aluminium-Thermoplastic Composite Joints by Plasma Electrolytic Oxidation Coating

Atiyeh Adelinia is a PhD student in the Department of Surface Technology and Tribology. (Co)Promotors are prof.dr.ir. M.B. de Rooij, dr. J. Monfared and dr. D.T.A. Matthews from the Faculty of Engineering Technology.

How can lightweight materials make future vehicles more energy-efficient without compromising safety and performance? Hybrid structures that combine aluminium with fibre-reinforced thermoplastics offer significant potential for reducing the weight of cars and aircraft, leading to lower fuel consumption and reduced CO₂ emissions. However, the interface between the metal and the thermoplastic often determines the reliability and long-term performance of these structures.

In her PhD research, Atiyeh explores the use of plasma electrolytic oxidation (PEO) as a surface treatment to enhance adhesion in directly bonded metal–thermoplastic composite hybrids. By creating a porous oxide layer with tailored surface properties, PEO enables the molten thermoplastic to mechanically interlock to the metal surface during direct bonding, eliminating the need for adhesives or mechanical fasteners.

The research provides fundamental insight into the effect of microstructure and chemistry of PEO coatings on adhesion in the hybrid joints. Moreover, by systematically relating coating characteristics to the bonding behaviour of different thermoplastic composites, the work demonstrates how surface engineering can be used to optimise interfacial strength.

These findings contribute to the development of stronger, more reliable, and more sustainable lightweight hybrid structures for automotive and aerospace applications.