Investigating the Application of Epoxy Adhesive Monomer Diffusion in Thermoplastic Surface Layers for Structural Bonding of FRPs

This study explores the potential of integrating thermoplastic surfaces into fiber-reinforced plastics (FRPs) to eliminate the need for extensive surface preparation prior to bonding. Traditional bonding techniques for FRPs, especially in aerospace applications, demand meticulous surface preparation to ensure adequate adhesion. As a potential alternative to conventional methods for generating adhesion, the formation of an interpenetrating polymer network (IPN) by diffusion of the epoxy monomers into a thermoplastic surface layer is investigated. The research involved manufacturing CFRP panels with thermoplastic surfaces, polyether sulfone (PES), and polyetherimide (PEI), followed by a bonding process with and without conventional surface preparation. The performance of the joints was tested by tensile shear and Mode-I fracture toughness tests and compared to reference samples without thermoplastic surfaces. The formation and characteristics of the IPNs were analyzed using optical microscopy, laser scanning microscopy, and energy-dispersive X-ray spectroscopy. The results demonstrate that PES surfaces, even without surface treatment, can provide high mechanical performance with shear strengths ranging from 18 MPa to 23 MPa. PEI surfaces led to a shear strength from 10 MPa up to 14 MPa, correlating to a less extensive IPN formation compared to PES. However, both thermoplastics significantly improved the bonding process performance without surface preparation.