Welding of polymer composites, for like-material (composite/composite) and dissimilar (composite/metal) combinations, is a promising alternative to conventional joining methods in sectors such as aerospace and automotive, yet achieving robust joints is critically dependent on optimal interfacial bonding. The primary objective of this systematic review is to evaluate the comparative effectiveness of surface treatment strategies applied prior to welding, based on material properties, process variables, and application contexts. Employing a bibliometric and SWOT analysis, this study categorizes techniques into seven main groups: abrasive, laser texturing, plasma, etching, chemical oxidation, intermediate film application, and nanofiller incorporation. These methods are assessed by how they modify surface properties to enhance mechanical anchoring and chemical interactions. The analysis reveals a multifaceted choice of treatment, highly dependent on the specific materials and welding process, with recurring effective strategies: for like-material joints, robust performance is achieved through compatible thermoplastic films, often combined with plasma or nanofillers, whereas for dissimilar joints, an effective combination strategy frequently involves abrasive preparation, oxide layer growth, and silane deposition to increase roughness and chemical compatibility. This review establishes that engineered surface treatments and their strategic combinations are fundamental for enabling reliable, high-performance welded joints, thereby advancing the application of lightweight composite structures.
TalrejaRWaasAM. Concepts and definitions related to mechanical behavior of fiber reinforced composite materials. Compos Sci Technol2022; 217: 109081. https://doi.org/10.1016/j.compscitech.2021.109081
2.
SharmaHKumarARanaS, et al.Critical review on advancements on the fiber-reinforced composites: role of fiber/matrix modification on the performance of the fibrous composites. J Mater Res Technol2023; 26: 2975–3002. https://doi.org/10.1016/j.jmrt.2023.08.036
3.
BotelhoECAlmeidaRSPardiniLC, et al.Influence of hygrothermal conditioning on the elastic properties of carall laminates. Appl Compos Mater2007; 14: 209–222. https://doi.org/10.1007/s10443-007-9041-3
4.
FariaMCMDAppezzatoFCCostaML, et al.The effect of the ocean water immersion and UV ageing on the dynamic mechanical properties of the PPS/glass fiber composites. J Reinforc Plast Compos2011; 30: 1729–1737. https://doi.org/10.1177/0731684411427483
5.
SantosALBotelhoECKostovKG, et al.Atmospheric plasma treatment of carbon fibers for enhancement of their adhesion properties. IEEE Trans Plasma Sci2013; 41: 319–324. https://doi.org/10.1109/TPS.2012.2234484
6.
SantosALNakazatoRZSchmeerS, et al.Influence of anodization of aluminum 2024 T3 for application in aluminum/Cf/epoxy laminate. Compos B Eng2020; 184: 107718. https://doi.org/10.1016/j.compositesb.2019.107718
ZhaoTPalardyGVillegasIF, et al.Mechanical behaviour of thermoplastic composites spot-welded and mechanically fastened joints: a preliminary comparison. Compos B Eng2017; 112: 224–234. https://doi.org/10.1016/j.compositesb.2016.12.028
10.
LiuSWangYFanT, et al.The influence of process parameters and carbon nanotubes on composite material joints. Polym Compos2024; 45: 14875–14887. https://doi.org/10.1002/pc.28807
11.
HeathmanNKoiralaPYapT, et al.In situ consolidation of carbon fiber PAEK via laser-assisted automated fiber placement. Compos B Eng2023; 249: 110405. https://doi.org/10.1016/j.compositesb.2022.110405
12.
ŞişmanoğluSGürcanATYildirim-BilmezZ, et al.Effect of surface treatments and universal adhesive application on the microshear bond strength of CAD/CAM materials. Journal of Advanced Prosthodontics2020; 12: 22–32. https://doi.org/10.4047/jap.2020.12.1.22
13.
TijsBHAHTuronABisagniC. Characterization and analysis of conduction welded thermoplastic composite joints considering the influence of manufacturing. Compos Struct2024; 348: 118505. https://doi.org/10.1016/j.compstruct.2024.118505
14.
CayirSKamanMOAlbayrakM. Effect of nonlinear material behavior on progressive failure analysis of pin-joint composites. Mech Base Des Struct Mach2024; 52: 2929–2955. https://doi.org/10.1080/15397734.2023.2194380
15.
FrederickHLiWPalardyG. Disassembly study of ultrasonically welded thermoplastic composite joints via resistance heating. Materials2021; 14: 2521. https://doi.org/10.3390/ma14102521
16.
VigneshNJNavasinghRJHPitchumaniSV, et al.Optimization and microstructural study of friction riveted carbon-Kevlar and aluminum joints for aerospace applications. Sci Rep2025; 15: 7060. https://doi.org/10.1038/s41598-025-89357-7
17.
AkalınYDilsizNÖzgürDÖ. Investigating the bonding performance of metal-CFRP hybrid composites: a study on aircraft components. Polym Compos2024; 46: 6623–6633. https://doi.org/10.1002/pc.29382
18.
MurzinSPPalkowskiHMelnikovAA, et al.Improving the quality of laser-welded butt joints of metal–polymer sandwich composites. Appl Sci2022; 12: 7099. https://doi.org/10.3390/app12147099
19.
BolatÇAslanMTÇebiA, et al.A comprehensive analysis of the influence of adhesive types and layer stacking sequence on tensile and impact responses of ASA/PLA composite sandwich structures by additive manufacturing. J Polym Res2025; 32: 174. https://doi.org/10.1007/s10965-025-04403-2
20.
TroschitzJGrögerBWürfelV, et al.Joining processes for fibre-reinforced thermoplastics: phenomena and characterisation. Materials2022; 15: 5454. https://doi.org/10.3390/ma15155454
21.
PeriasamyKKandareEDasR, et al.Interfacial engineering methods in thermoplastic composites: an overview. Polymers2023; 15: 415. https://doi.org/10.3390/polym15020415
22.
KwonDJKimNSRJangYJ, et al.Impacts of thermoplastics content on mechanical properties of continuous fiber-reinforced thermoplastic composites. Compos B Eng2021; 216: 108859. https://doi.org/10.1016/j.compositesb.2021.108859
23.
DaweiZQiZXiaoguangF, et al.Review on Joining Process of Carbon Fiber-Reinforced Polymer and Metal: Methods and Joining Process. Rare Metal Mat Eng2018; 47: 3686–3696.
ChenCZhangWLiY, et al.The influence of moisture absorption-drying of composite materials on the bonding performance of the joints. Macromol Mater Eng2023; 308: 2200463. https://doi.org/10.1002/mame.202200463
26.
RakeshPKKumarRDixitA, et al.Effect of mechanical fastening versus adhesively bonded joints of polymer composites on lap joint strength. J Adv Manuf Syst2024; 23: 683–695. https://doi.org/10.1142/S021968672450029X
GotoKImaiKAraiM, et al.Shear and tensile joint strengths of carbon fi ber-reinforced thermoplastics using ultrasonic welding. Composites Part A2019; 116: 126–137. https://doi.org/10.1016/j.compositesa.2018.10.032
29.
HaqueR. Quality of self-piercing riveting (SPR) joints from cross-sectional perspective: a review. Arch Civ Mech Eng2018; 18: 83–93. https://doi.org/10.1016/j.acme.2017.06.003
30.
XiongXZhaoPRenR, et al.Enhanced resistance-welding hybrid joints of titanium alloy/thermoplastic composites using a carbon-nanotube lamina. Diam Relat Mater2020; 101: 107611. https://doi.org/10.1016/j.diamond.2019.107611
31.
FarahaniRDDubéM. Novel heating elements for induction welding of carbon fiber/polyphenylene sulfide thermoplastic composites. Adv Eng Mater2017; 19: 1700294. https://doi.org/10.1002/adem.201700294
32.
Hossein AbadiRRefah TorunAMohammadali Zadeh FardA, et al.Fracture characteristics of mixed-mode toughness of dissimilar adherends (cohesive and interfacial fracture). J Adhes Sci Technol2020; 34: 599–615. https://doi.org/10.1080/01694243.2019.1674102
33.
PramanikABasakAKDongY, et al.Joining of carbon fibre reinforced polymer (CFRP) composites and aluminium alloys – a review. Compos Part A Appl Sci Manuf2017; 101: 1–29. https://doi.org/10.1016/j.compositesa.2017.06.007
34.
BhudoliaSKGohelGLeongKF, et al.Advances in ultrasonicwelding of thermoplastic composites: a review. Materials2020; 13. https://doi.org/10.3390/ma13061284
35.
XiongXWangDWeiJ, et al.Resistance welding technology of fiber reinforced polymer composites: a review. J Adhes Sci Technol2021; 35: 1593–1619. https://doi.org/10.1080/01694243.2020.1856514
36.
ParanjpeNUddinMNRahmanAS, et al.Effects of surface treatment on adhesive performance of composite-to-composite and composite-to-metal joints. Processes2024; 12: 2623. https://doi.org/10.3390/pr12122623
Droździel-JurkiewiczMBieniaśJ. Evaluation of surface treatment for enhancing adhesion at the metal–composite interface in fibre metal-laminates. Materials2022; 15: 6118. https://doi.org/10.3390/ma15176118
39.
PerrinHMertzGSenoussaouiN-L, et al.Surface functionalization of thermoset composite for infrared hybrid welding. Functional Composite Materials2021; 2: 10. https://doi.org/10.1186/s42252-021-00021-5
40.
SharmaAMaheshwariSKhannaP. Surface composite fabrication by friction stir processing: a review. E3S Web of Conferences2021; 309: 01150. https://doi.org/10.1051/e3sconf/202130901150
41.
Frank ReisJCintraILRMarquesLFB, et al.Study on YB-laser welding applied on aluminum/polymer composites. J Adhes Sci Technol2023; 38: 716–737. https://doi.org/10.1080/01694243.2023.2241634
42.
HegemannDBülbülEHanselmannB, et al.Plasma polymerization of hexamethyldisiloxane: revisited. Plasma Process Polym2021; 18: 2000176. https://doi.org/10.1002/ppap.202000176
De Oliveira HeinLRDe OliveiraJADe CamposKA, et al.Extended depth from focus reconstruction using NIH ImageJ plugins: quality and resolution of elevation maps. Microsc Res Tech2012; 75: 1593–1607. https://doi.org/10.1002/jemt.22105
45.
GentANLinCW. Model studies of the effect of surface roughness and mechanical interlocking on adhesion. J Adhes1990; 32: 113–125. https://doi.org/10.1080/00218469008030185
46.
StankiewiczKLipkowskiAKowalczykP, et al.Resistance welding of thermoplastic composites, including welding to thermosets and metals: a review. Materials2024; 17: 4797. https://doi.org/10.3390/ma17194797
47.
ZhaoGLiMZhaoY, et al.Rotating gliding arc plasma: innovative treatment for adhesion improvement between stainless steel heating elements and thermoplastics in resistance welding of composites. Compos B Eng2024; 272: 111210. https://doi.org/10.1016/J.COMPOSITESB.2024.111210
48.
JiangBChenQYangJ. Advances in joining technology of carbon fiber-reinforced thermoplastic composite materials and aluminum alloys. Int J Adv Manuf Technol2020; 110: 2631–2649. https://doi.org/10.1007/s00170-020-06021-2/Published
GardinerG. Thermoplastic composites gain leading edge on the A380. High Perform Compos2006; 14: 50–55.
51.
TotlaHSGuptaAMishraS, et al.Resistance welding analysis of thermoplastic composite structures in aeronautical applications. Int J Interact Des Manuf2023. https://doi.org/10.1007/s12008-022-01151-1
52.
MartínIFernándezKCuencaJ, et al.Design and manufacture of a reinforced fuselage structure through automatic laying-up and in-situ consolidation with co-consolidation of skin and stringers using thermoplastic composite materials. Heliyon2023; 9: e12728. https://doi.org/10.1016/j.heliyon.2022.e12728
53.
ChenP. An economical surface treatment for improving resistance welding strength of carbon fiber/epoxy composites. J Thermoplast Compos Mater2025; 39: 1095–1135. https://doi.org/10.1177/08927057251361023
54.
MurrayREPlumerABeachR, et al.Validation of a lightning protection system for a fusion-welded thermoplastic composite wind turbine blade tip. Wind Eng2022; 46: 260–272. https://doi.org/10.1177/0309524X211024642
55.
DuKHuangJLiC, et al.The bonding strength of polyamide-6 direct adhesion with anodized AA5754 aluminum alloy. J Thermoplast Compos Mater2022; 35: 1852–1865. https://doi.org/10.1177/0892705720939139
56.
ManenteANGoushegirSMScharnaglN, et al.Composite surface pre-treatments: improvement on adhesion mechanisms and mechanical performance of metal–composite friction spot joints with additional film interlayer. J Adhes2018; 94: 723–742. https://doi.org/10.1080/00218464.2017.1378101
57.
AnagrehNDornLBilke-KrauseC. Low-pressure plasma pretreatment of polyphenylene sulfide (PPS) surfaces for adhesive bonding. Int J Adhes Adhes2008; 28: 16–22. https://doi.org/10.1016/j.ijadhadh.2007.03.003
58.
ZhaoYZhaoGLiM, et al.The effect of surface treatment on the resistance welding technology for carbon fiber/epoxy resin composites. Appl Compos Mater2024; 31: 201–221. https://doi.org/10.1007/s10443-023-10165-1
59.
RohartVLaberge LebelLDubéM. Improved adhesion between stainless steel heating element and PPS polymer in resistance welding of thermoplastic composites. Compos B Eng2020; 188: 107876. https://doi.org/10.1016/j.compositesb.2020.107876
60.
XiongXZhaoPRenR, et al.Effect of chemical etching of resistance wire surface on the strength and failure mechanism of the resistance-welded joint of polyetherimide composites. J Appl Polym Sci2019; 136: 47879. https://doi.org/10.1002/app.47879
61.
XiongXZhaoPRenR, et al.Design of reinforced interfacial structure in hybrid resistance-welded joints of GF/PEI composite and Ti6Al4V alloy by pre-etching surface treatment combined with in-situ growth of CNTs. Eng Res Express2019; 1: 015023. https://doi.org/10.1088/2631-8695/AB38CF
62.
XiongXWangDRenR, et al.Improved mechanical properties of resistance welded joints of thermoplastic composites by versatile graphene oxide. J Adhes Sci Technol2021; 35: 1099–1113. https://doi.org/10.1080/01694243.2020.1834288
63.
Dal ConteUFF VillegasITachonJ. Ultrasonic plastic welding of CF/PA6 composites to aluminium: process and mechanical performance of welded joints. J Compos Mater2019; 53: 2607–2621. https://doi.org/10.1177/0021998319836022
64.
TirbandHAkbariDFaraji KalajahiP. Improving the quality of the ultrasonic welded thermoset-based composites using laser surface treatment. Proc Inst Mech Eng Part L2024; 238: 1669–1676. https://doi.org/10.1177/14644207241230757
KimuraHYamaguchiTTsubokawaM, et al.A study on the glassfiber reinforcement effect of F.R.P.E and on the behavior of it’s welded part. The Japan Society of Mechanical Engineers1969; 35: 6–13.
68.
TaylorNSWatsonMN. Welding techniques for plastics and composites. Joining & Materials1988; 1: 70–73.
Chan-ParkMBNgewH-SYipDCF, et al.Heating methods for bonding thermoplastics to aluminum alloy. J Adv Mater2001; 33: 52–61.
71.
VolkovSSGaraninINKholopovYV. Ultrasonic welding of different types of plastic using a thermoplastic liner and the effect of the surface roughness on the weldability. Russ Ultrason1997; 27: 71–77.
72.
GehdeMGieseMEhrensteinGW. Welding of thermoplastics reinforced with random glass mat. Polym Eng Sci1997; 37: 702–714. https://doi.org/10.1002/pen.11714
73.
da CostaAPBotelhoECCostaML, et al.A review of welding technologies for thermoplastic composites in aerospace applications. J Aero Technol Manag2012; 4: 255–265. https://doi.org/10.5028/JATM.2012.04033912
ShiHVillegasIFBerseeHEN. Strength and failure modes in resistance welded thermoplastic composite joints: effect of fibre-matrix adhesion and fibre orientation. Compos Part A Appl Sci Manuf2013; 55: 1–10. https://doi.org/10.1016/j.compositesa.2013.08.008
ShiHFernandez VillegasIBerseeH. Effect of fibre-matrix adhesion and fibre orientation on thermoplastic composite welded joints. n.d.
78.
AgeorgesCYeLHouM. Experimental investigation of the resistance welding of thermoplastic-matrix composites. Part II: optimum processing window and mechanical performance. Compos Sci Technol2000; 60: 1191–1202. https://doi.org/10.1016/S0266-3538(00)00025-7
79.
PalardyGVillegasIF. On the effect of flat energy directors thickness on heat generation during ultrasonic welding of thermoplastic composites. Compos Interfaces2017; 24: 203–214. https://doi.org/10.1080/09276440.2016.1199149
80.
ReisJFAbrahaoABMCostaML, et al.Assessment of the interlaminar strength of resistance-welded PEI/carbon fibre composite. Weld Int2018; 32: 149–160. https://doi.org/10.1080/09507116.2017.1347329
SiddiqueAIqbalZNawabY, et al.A review of joining techniques for thermoplastic composite materials. J Thermoplast Compos Mater2022; 36: 3417–3454. https://doi.org/10.1177/08927057221096662
83.
AgeorgesCYeLHouM. Advances in fusion bonding techniques for joining thermoplastic matrix composites: a review. Compos Part A Appl Sci Manuf2001; 32: 839–857. https://doi.org/10.1016/S1359-835X(00)00166-4
84.
LambiaseFScipioniSILeeCJ, et al.A state-of-the-art review on advanced joining processes for metal-composite and metal-polymer hybrid structures. Materials2021; 14: 1890. https://doi.org/10.3390/ma14081890
85.
BoseSChelladuraiHPonappaK. A review on recent developments in ultrasonic welding of polymers and polymeric composites. Weld World2024; 68: 1881–1903. https://doi.org/10.1007/s40194-024-01693-w
86.
ZhangZWangXLuoY, et al.Study on heating process of ultrasonic welding for thermoplastics. J Thermoplast Compos Mater2010; 23: 647–664. https://doi.org/10.1177/0892705709356493
87.
RazaSFKhanSAMughalMP. Optimizing the weld factors affecting ultrasonic welding of thermoplastics. Int J Adv Manuf Technol2019; 103: 2053–2067. https://doi.org/10.1007/s00170-019-03681-7
88.
RubinoFParmarHManciaT, et al.Ultrasonic welding of glass reinforced epoxy composites using thermoplastic hybrid interlayers. Compos Struct2023; 314: 116980. https://doi.org/10.1016/j.compstruct.2023.116980
ZhangXXWuLHAndräH, et al.Effects of welding speed on the multiscale residual stresses in friction stir welded metal matrix composites. J Mater Sci Technol2019; 35: 824–832. https://doi.org/10.1016/j.jmst.2018.11.005
91.
MeyghaniBAwangMBEmamianSS, et al.A comparison of different finite element methods in the thermal analysis of friction stir welding (FSW). Metals2017; 7: 1–23. https://doi.org/10.3390/met7100450
92.
GuoYZhaoHAiC, et al.Parameter optimization of friction stir spot welded Al 6061 and CFRTP PA6 with surface treatment and interfacial adhesion. Thin-Walled Struct2024; 197: 111585. https://doi.org/10.1016/J.TWS.2024.111585
93.
SunYChenJGuanK, et al.Study on pretreatment groove and multi-walled carbon nanotubes-filled friction stir lap welding for 6061-T6 Al alloy and carbon fiber-reinforced polymer composite. Polym Compos2025; 47: 4819–4831. https://doi.org/10.1002/pc.70466
94.
PanneerselvamKAravindanSNoorul HaqA. Study on resistance welding of glass fiber reinforced thermoplastic composites. Mater Des2012; 41: 453–459. https://doi.org/10.1016/J.MATDES.2012.05.025
95.
HowieIGillespieJWSmileyAJ, et al.Resistance welding of graphite-Polyarylsulfone/Polysulfone dual-polymer composites. J Thermoplast Compos Mater1993; 6: 205–225. https://doi.org/10.1177/089270579300600303
ModiVBandaruAKRamaswamyK, et al.Repair of impacted thermoplastic composite laminates using induction welding. Polymers2023; 15: 3238. https://doi.org/10.3390/polym15153238
QinXYuTLiS, et al.A study on the formation and failure mechanisms of CF/PPS-metal induction welding joints strengthened by micro-pins. J Thermoplast Compos Mater2024; 37: 3540–3569. https://doi.org/10.1177/08927057241236140
100.
YunZXuHNieS, et al.Effect of process parameters and temperature on delamination propagation of resistance-welded thermoplastic composites. Polym Compos2025; 47: 2537–2549. https://doi.org/10.1002/pc.70304
101.
AughLGillespieJWFinkBK. Degradation of continuous carbon fiber reinforced polyetherimide composites during induction heating. J Thermoplast Compos Mater2001; 14: 96–115. https://doi.org/10.1106/LNR5-QDA0-QKKC-K16R
102.
NiZZhangGXueS, et al.Surface micro-welding strategy of h-BN assembled microspheres for composites with desirable thermal conductivity and a low dielectric constant. Ceram Int2024; 50: 50067–50076. https://doi.org/10.1016/j.ceramint.2024.09.353
103.
HuJYangTWuD, et al.Rapid fabrication of high strength PEEK/CNTs composites with segregated structure and weld repair through microwave sintering. Compos Part A Appl Sci Manuf2026; 200: 109333. https://doi.org/10.1016/j.compositesa.2025.109333
104.
ZoughiRArias-MonjePJGallionJ, et al.Microwave dielectric properties and Targeted heating of polypropylene nano-composites containing carbon nanotubes and carbon black. Polymer (Guildf)2019; 179: 121658. https://doi.org/10.1016/j.polymer.2019.121658
105.
HusseinSKMhessanANAlwanMA. Hot press joining optimization of polyethylene to Aluminium Alloy AA6061-T6 lap joint using design of experiments. Eng J2017; 21: 157–169. https://doi.org/10.4186/ej.2017.21.7.157
106.
TafreshiOAHoaSVShadmehriF, et al.Heat transfer analysis of automated fiber placement of thermoplastic composites using a hot gas torch. Adv Manuf Polym Compos Sci2019; 5: 206–223. https://doi.org/10.1080/20550340.2019.1686820
107.
ZhaoZYangZZhangW, et al.Low-velocity impact response and infrared radiation characteristics of thermoplastic/thermoset composites. Chin J Aeronaut2022; 35: 365–380. https://doi.org/10.1016/j.cja.2022.03.003
108.
JiaoJXuJJingC, et al.Laser welding process and strength enhancement of carbon fiber reinforced thermoplastic composites and metals dissimilar joint: a review. Chin J Aeronaut2023; 36: 13–31. https://doi.org/10.1016/j.cja.2023.02.025
109.
ReisJFMarquesLFBAbrahaoABM, et al.Feasibility study of the Oxy Fuel Gas Welding (OFW) process in AA2024-T3 and GF/PEI composite joint. Weld World2021: 1–10. https://doi.org/10.1007/s40194-021-01091-6
LiuMKYanCZhuYuanYDQPChenGLiuDXuHBShenJN. Research progress on hot-melt joining of fiber reinforced thermoplastic resin matrix composites and metal. Polym. Bull. (in Chinese). 2024; 37(11): 1535–1549. https://doi.org/10.14028/j.cnki.1003-3726.2024.24.130
112.
Kalyan KumarROmkumarM. Investigation of ultrasonic welding of carbon fiber reinforced thermoplastic to an aluminum alloy using a interfacial coating. Mater Manuf Process2021; 36: 1323–1331. https://doi.org/10.1080/10426914.2021.1905839
113.
KarunagaranNRajaduraiA. Effect of surface treatment on mechanical properties of glass fiber/stainless steel wire mesh reinforced epoxy hybrid composites. J Mech Sci Technol2016; 30: 2475–2482. https://doi.org/10.1007/S12206-016-0507-9/METRICS
114.
LiuZLiYLiuW, et al.Enhancing the ultrasonic plastic welding strength of Al/CFRTP joint via coated metal surface and structured composite surface. J Manuf Process2023; 108: 227–237. https://doi.org/10.1016/j.jmapro.2023.11.001
115.
FengWAroucheMMPavlovicM. Influence of surface roughness on the mode II fracture toughness and fatigue resistance of bonded composite-to-steel joints. Constr Build Mater2023; 411: 134358. https://doi.org/10.1016/j.conbuildmat.2023.134358
116.
BechikhAKlinkovaOMaalejY, et al.Effect of dry abrasion treatments on composite surface quality and bonded joints shear strength. Int J Adhes Adhes2022; 113: 103058. https://doi.org/10.1016/j.ijadhadh.2021.103058
117.
MoranoCTaoRAlfanoM, et al.Effect of mechanical pretreatments on damage mechanisms and fracture toughness in cfrp/epoxy joints. Materials2021; 14: 1512. https://doi.org/10.3390/ma14061512
118.
GoushegirSMdos SantosJFAmancio-FilhoST. Influence of aluminum surface pre-treatments on the bonding mechanisms and mechanical performance of metal-composite single-lap joints. Weld World2017; 61: 1099–1115. https://doi.org/10.1007/s40194-017-0509-y
119.
EstevesJVGoushegirSMdos SantosJF, et al.Friction spot joining of aluminum AA6181-T4 and carbon fiber-reinforced poly(phenylene sulfide): effects of process parameters on the microstructure and mechanical strength. Mater Des2015; 66: 437–445. https://doi.org/10.1016/j.matdes.2014.06.070
120.
ShimamotoKSekiguchiYSatoC. Effects of surface treatment on the critical energy release rates of welded joints between glass fiber reinforced polypropylene and a metal. Int J Adhes Adhes2016; 67: 31–37. https://doi.org/10.1016/J.IJADHADH.2015.12.022
121.
LeeH-YQuJ. An Interpretation of the Failure Paths of Roughened Metal/Polymer Interfaces. Met Mater Int2001; 7: 101–105.
122.
XuZYipWDongZ, et al.On the laser surface pre-treatment to enhance the surface texture, wettability and adhesion bonding strength of aluminium 7075-T6 laminates. Compos Interfaces2024; 31: 123–141. https://doi.org/10.1080/09276440.2023.2235804
123.
UşakACKaynakC. Improving film adhesive joining performance of poly(phenylene sulfide)/carbon fiber thermoplastic composite laminates by plasma surface treatment. J Thermoplast Compos Mater2024; 37: 1690–1729. https://doi.org/10.1177/08927057231200009
124.
AliheidariNAmeliA. Retaining high fracture toughness in aged polymer composite/adhesive joints through optimization of plasma surface treatment. Compos Part A Appl Sci Manuf2024; 176: 107835. https://doi.org/10.1016/j.compositesa.2023.107835
125.
LambiaseFYanalaPBLeoneC, et al.Influence of laser texturing strategy on thermomechanical joining of AA7075 aluminum alloy and PEEK. Compos Struct2023; 315: 116974. https://doi.org/10.1016/j.compstruct.2023.116974
126.
WangLRongYWuC, et al.Improving the joint strength of laser-welded CFRTP/TC4 joints via appropriate groove design. Appl Surf Sci2024; 644: 158752. https://doi.org/10.1016/J.APSUSC.2023.158752
127.
SteinerGKuttnerDLochnerH, et al.Optimization of hot gas welding of hybrid thermoplastic-thermoset composites using taguchi method. Appl Compos Mater2024; 31: 775–797. https://doi.org/10.1007/s10443-024-10208-1
128.
LiuMChenYZhangY, et al.Weldability improvement of immiscible polycarbonate/GFRP by femtosecond laser surface treatment. J Mater Process Technol2023; 318: 118033. https://doi.org/10.1016/j.jmatprotec.2023.118033
129.
EncinasNOakleyBRBelcherMA, et al.Surface modification of aircraft used composites for adhesive bonding. Int J Adhes Adhes2014; 50: 157–163. https://doi.org/10.1016/j.ijadhadh.2014.01.004
130.
ShentonMJStevensGC. Surface modification of polymer surfaces: atmospheric plasma versus vacuum plasma treatments. J Phys D Appl Phys2001; 34: 2761–2768. https://doi.org/10.1088/0022-3727/34/18/308
131.
FernandesJCSFerreiraMGSHaddowDB, et al.Plasma-polymerised coatings used as pre-treatment for aluminium alloys. Surf Coat Technol2002; 154: 8–13. https://doi.org/10.1016/s0257-8972(01)01705-4
132.
LucasRRDe CássiaRSales-ContiniM, et al.Characterization of the hybrid joint between AA2024-T3 alloy and thermoplastic composite obtained by oxy-fuel welding (OFW). 2024. https://doi.org/10.3934/matersci.2024029
133.
NagarajanBMManoharanM. Assessment of dissimilar joining between metal and polymer hybrid structure with different joining processes. J Thermoplast Compos Mater2023; 36: 2169–2211. https://doi.org/10.1177/08927057211048534
134.
SundriyalPSahuMPrakashO, et al.Long-term surface modification of PEEK polymer using plasma and PEG silane treatment. Surf Interfaces2021; 25: 101253. https://doi.org/10.1016/J.SURFIN.2021.101253
135.
IqbalHMSBhowmikSBenedictusR. Surface modification of high performance polymers by atmospheric pressure plasma and failure mechanism of adhesive bonded joints. Int J Adhes Adhes2010; 30: 418–424. https://doi.org/10.1016/j.ijadhadh.2010.02.007
136.
WangTGongBHuW, et al.Correlation between interfacial bonding behavior and surface treatments in bonded carbon fiber composite joints. Polym Compos2025; 46: 9410–9422. https://doi.org/10.1002/pc.29566
137.
TangHShiWDingY, et al.Experimental investigation and molecular dynamics simulations of plasma treatment on the interface strength of overmolded hybrid fiber reinforced polypropylene composites. Polym Compos2022; 43: 1799–1808. https://doi.org/10.1002/pc.26498
138.
HegemannDBrunnerHOehrC. Plasma Treatment of Polymers to Generate Stable, Hydrophobic Surfaces. Plasmas and Polymers2001; 6: 221–235.
139.
ChengXSuGDuB, et al.Resistance welding process for glass fiber-reinforced polypropylene composite joints: parameter optimization and performance assessment. Polym Compos2025; 46: 10376–10388. https://doi.org/10.1002/pc.29627
140.
LuBZQiaoYNickersonEK, et al.Improving adhesive bonding of short carbon fiber thermoplastic composites to aluminum alloys with a hybrid laser-plasma surface modification strategy. Mater Des2025; 257: 114501. https://doi.org/10.1016/j.matdes.2025.114501
141.
LiuHSunJDuanZ, et al.Study on properties influence of carbon fiber reinforced polyimide composites via surface modification using metal mesh. Polym Compos2023; 44: 971–979. https://doi.org/10.1002/pc.27147
142.
HegemannDVohrerUOehrC, et al.Deposition of SiO x films from O 2/HMDSO plasmas. Surf Coat Technol1999; 116–119: 1033–1036.
143.
DuBZhouXLiQ, et al.Surface treat method to improve the adhesion between stainless steel and resin: a review. ACS Omega2023; 8: 39984–40004. https://doi.org/10.1021/acsomega.3c05728
144.
DominguesLOliveiraCFernandesJCS, et al.EIS on plasma-polymerised coatings used as pre-treatment for aluminium alloys. Electrochim Acta2002; 47: 2253–2258. https://doi.org/10.1016/s0013-4686(02)00064-6
145.
LucasRRSilvaERRMarquesLFB, et al.Analysis of plasma electrolytic oxidation process parameters for optimizing adhesion in aluminum–composite hybrid structures. Appl Sci2024; 14: 7972. https://doi.org/10.3390/app14177972
146.
LucasRRMarquesLFBHeinLRDO, et al.Experimental design of the adhesion between a PEI/glass fiber composite and the AA1100 aluminum alloy with oxide coating produced via Plasma Electrolytic Oxidation (PEO). Ceramics2024; 7: 596–606. https://doi.org/10.3390/CERAMICS7020039
147.
LinYLiHWangQ, et al.Effect of plasma surface treatment of aluminum alloy sheet on the properties of Al/Gf/PP laminates. Appl Surf Sci2020; 507: 145062. https://doi.org/10.1016/j.apsusc.2019.145062
148.
MascagniDBTDe SouzaMEPDe Alvarenga FreireCM, et al.Corrosion resistance of 2024 aluminum alloy coated with plasma deposited a-C:H:Si:O films. Mater Res2014; 17: 1449–1465. https://doi.org/10.1590/1516-1439.289014
149.
JianL. Effect of surface treatment on enhancing interfacial strength of carbon fiber/polyimide composites. J Thermoplast Compos Mater2022; 35: 708–719. https://doi.org/10.1177/0892705720925141
150.
WangSWangWXuY, et al.Enhancing bonding synergy and mechanical response of metal/composite hybrid joints through physicochemical surface pretreatment. J Mater Process Technol2023; 315: 117923. https://doi.org/10.1016/J.JMATPROTEC.2023.117923
151.
XieYZhangJZhouT. Large-area mechanical interlocking via nanopores: ultra-high-strength direct bonding of polymer and metal materials. Appl Surf Sci2019; 492: 558–570. https://doi.org/10.1016/J.APSUSC.2019.06.246
152.
NiSSunLErcanB, et al.A mechanism for the enhanced attachment and proliferation of fibroblasts on anodized 316L stainless steel with nano-pit arrays. J Biomed Mater Res B Appl Biomater2014; 102: 1297–1303. https://doi.org/10.1002/JBM.B.33127
153.
PasiniSMBatistellaMAde SouzaSMAGU, et al.Thermal degradation and flammability of TiO2–polyetherimide nanocomposite fibers. Polym Bull2020; 77: 4937–4958. https://doi.org/10.1007/s00289-019-02970-1
ZhangZShanJGTanXH, et al.Effect of anodizing pretreatment on laser joining CFRP to aluminum alloy A6061. Int J Adhes Adhes2016; 70: 142–151. https://doi.org/10.1016/j.ijadhadh.2016.06.007
157.
AkpinarIAKoçyiğitÖFAtasoyS. Effect of oxidation and silane modifications applied to the bonded material and fibers in carbon-fiber-reinforced composite adhesive joints. Polymers2025; 17: 1893. https://doi.org/10.3390/polym17141893
158.
ZhangXFengZSuJ, et al.Achieving the adhesion improvement between heating elements and thermoplastics in resistance welding of composites via anodizing treatment. Thin-Walled Struct2025; 216: 113724. https://doi.org/10.1016/j.tws.2025.113724
159.
ShiXJinXYanN, et al.Influence of micro-oxidation on joints of C/C composites and GH3044 for large-size aerospace parts. Acta Astronaut2017; 140: 478–484. https://doi.org/10.1016/j.actaastro.2017.09.015
160.
DubéMHubertPYousefpourA, et al.Current leakage prevention in resistance welding of carbon fibre reinforced thermoplastics. Compos Sci Technol2008; 68: 1579–1587. https://doi.org/10.1016/J.COMPSCITECH.2007.09.008
161.
YanYZhangJZhangT, et al.Surface selective oxidation of C/C composites by ultrafast high-temperature shock for enhancing interfacial bonding with metal. J Eur Ceram Soc2024; 44: 3121–3130. https://doi.org/10.1016/j.jeurceramsoc.2023.12.062
162.
JothiVYusuf AdesinaAMadhan KumarA, et al.Influence of an anodized layer on the adhesion and surface protective performance of organic coatings on AA2024 aerospace Al alloy. Prog Org Coating2019; 138: 105396. https://doi.org/10.1016/j.porgcoat.2019.105396
163.
MaierhoferTLoukaidesEGCarrC, et al.Resistance-welded thermoset composites: a Bayesian approach to process optimisation for improved fracture toughness. Compos Part A Appl Sci Manuf2024; 177: 107894. https://doi.org/10.1016/J.COMPOSITESA.2023.107894
164.
XieLLiuHWuW, et al.Fusion bonding of thermosets composite structures with thermoplastic binder co-cure and prepreg interlayer in electrical resistance welding. Mater Des2016; 98: 143–149. https://doi.org/10.1016/j.matdes.2016.03.020
165.
MasBFernández-BlázquezJPDuvalJ, et al.Thermoset curing through Joule heating of nanocarbons for composite manufacture, repair and soldering. Carbon N Y2013; 63: 523–529. https://doi.org/10.1016/j.carbon.2013.07.029
166.
LiangYShiY. Computational and experimental study on the resistance welding process of a glass fiber-reinforced epoxy-based composite with thermoplastic interlayer adherent. Polym Compos2024; 45: 5096–5110. https://doi.org/10.1002/pc.28113
LiuSWangYWuZ, et al.Enhancing resistance welding strength of carbon fiber/polycaprolactam thermoplastic composites through coupling agent-modified metal heating elements. Polym Compos2025; 46: 3576–3594. https://doi.org/10.1002/pc.29192
169.
JungKWKawahitoYTakahashiM, et al.Laser direct joining of carbon fiber reinforced plastic to zinc-coated steel. Mater Des2013; 47: 179–188. https://doi.org/10.1016/j.matdes.2012.12.015
170.
YuJZhangBJinW, et al.Enhancing resistance-welded joints between 7075 Al alloy and CF/PEEK via thermoplastic interface strengthening. Polym Compos2025; 47: 2314–2325. https://doi.org/10.1002/pc.70283
171.
PanJQuanDYueD, et al.Enhancing ultrasonic welding joints of CF/PEEK composites and aluminum via pre-deposition of a PEEK layer onto the metal substrate. Polym Compos2025; 46: 16638–16650. https://doi.org/10.1002/pc.70057
172.
KimHJParkHJJeonM, et al.Enhancing interfacial adhesion and electrical conductivity of steel/polymer composites via molecular adhesion for sustainable structural materials. Surf Interfaces2024; 46: 103918. https://doi.org/10.1016/J.SURFIN.2024.103918
173.
LongWZhouXDuB, et al.Enhancing the lap shear performance of resistance-welded GF/PP thermoplastic composite by modifying metal heating elements with silane coupling agent. Materials2024; 17: 4944. https://doi.org/10.3390/ma17204944
174.
LiXSunMSongJ, et al.Enhanced adhesion between PEEK and stainless-steel mesh in resistance welding of CF/PEEK composites by various surface treatments. High Perform Polym2021; 33: 892–904. https://doi.org/10.1177/09540083211001115
175.
KumarJKumarVSinghI, et al.Joining behavior of polymeric composites fabricated using agricultural waste as fillers. J Adhes Sci Technol2021; 35: 1652–1663. https://doi.org/10.1080/01694243.2020.1855909
176.
TanakaKNishikawaTAotoK, et al.Effect of carbon nanotube deposition time to the surface of carbon fibres on flexural strength of resistance welded carbon fibre reinforced thermoplastics using carbon nanotube grafted carbon fibre as heating element. J Compos Sci2019; 3: 9. https://doi.org/10.3390/jcs3010009
177.
ZhaoPZhangZLiY, et al.Resistance welding of thermoplastic composites via a novel carbon nanofilm implant. Mater Lett2022; 328: 133216. https://doi.org/10.1016/j.matlet.2022.133216
178.
BrassardDDubéMTavaresJR. Modelling resistance welding of thermoplastic composites with a nanocomposite heating element. J Compos Mater2020; 55: 625–639. https://doi.org/10.1177/0021998320957055
179.
ParveezBKitturMIBadruddinIA, et al.Scientific advancements in composite materials for aircraft applications: a review. Polymers2022; 14: 5007. https://doi.org/10.3390/POLYM14225007
