Direct joining between nano-textured metal and non-crystalline polymer via heating and cooling injection molding

Non-crystalline transparent polymer could not directly join nano-textured metals via injection molded direct joining, in which molten polymer infiltrates into metal surface textures via injection molding to yield strong mechanical interlocking. This is mainly because non-crystalline polymer with higher glass-transition temperature indicates lower flowability during the injection molding. Here we propose to introduce heating and cooling injection molding to directly join them. We developed a heating and cooling mold system, and succeeded in joining PMMA with nano-textured aluminum alloy. We also found via design of experiments that mold temperature and packing pressure are dominant parameters to improve joining strength.