Improving the Interfacial Bonding Strength of Laser Direct Joining between Dissimilar 304 Stainless Steel and PCCF30 Plastic

In response to the issue of weak laser connection strength between 304 stainless steel and the carbon fiber-reinforced polymer PCCF30, this study proposes the addition of a polyethylene terephthalate (PET) intermediate layer between 304 stainless steel and PCCF30, along with surface texture pretreatment of the stainless steel surface, to enhance the joint connection strength. First, three types of surface textures (vertical, wavy, and vertical plus wave) were investigated for their effect on joint quality. Once the optimal texture type was determined, the effect of texture scanning repetition on the surface morphology and groove cross-sectional geometry of 304 stainless steel was examined. The joint strengths achieved by adding intermediate layers and employing different surface texture treatment methods were compared, followed by a comparison of the joint strengths obtained from different pretreatment methods. Finally, the connection mechanism of the joint was analyzed. The results indicated that the maximum joint strength achieved through the vertical and wavy texture design was 4.39 MPa, which is 3.3 times greater than that achieved without reinforcement. Moreover, the maximum joint strength achieved with the addition of a PET intermediate layer and surface texture composite treatment was 11.85 MPa, which is approximately nine times greater than that achieved via direct connection. The inclusion of a PET intermediate layer enhances the fluidity of the molten polymer at the joint, facilitating better filling of the grooves with surface texture. This strengthens the mechanical anchoring effect of the joint and contributes to the improvement in the joint’s connection strength. An XPS analysis revealed that after multiple etchings of the joint interface with an added intermediate layer, the Cr in the stainless steel chemically bonded with the PET, resulting in the formation of Cr–O–C chemical bonds, which is advantageous for enhancing joint quality.