Anodized Ti-6Al-HV/adhesive bonds exhibit improved corrosion resistance and a higher strength-to-weight ratio compared to conventional metal bonding techniques for primary and/or secondary structural applications. This work was conducted to identify chromic acid (CA) anodization and bond process conditions which produced durable, structural anodized Ti-6Al-4V/heat resistant single lap bonds and to understand why these conditions were necessary. A structural single lap bond was defined as a bond tested at 298K ≤ 0.5 month after bonding and with a strength ≥ 6.9 MPa, based upon values reported in structural adhesive manufacturers' product literature. A durable, structural single lap bond was defined as a bond with a strength ≥ 6.9 MPa strength at 298K after 9 months aging at 433K. Heat resistant adhesives tested had reported service temperatures ≥ 423K, and were: polysulfone; eolyethersulfone; polyphenylquinoxaline; polyetherimide, both unfilled and 20% glass filled; and 50% calcium carbonate filled polyimide.

Hydrofluoric acid (HF) added to the CA anodization solution was necessary to produce structural bonds. CA/HF oxide was more porous, and thicker than the CA anodic oxide (140 nm vs. 20 nm), perhaps promoting physical and oxide/adhesive interphase mechanical interlock. Structural, durable CA/HF anodized Ti-6Al-4V-adhesive bonds were produced for all adhesives tested except for the filled polyimide (5.5 MPa). The filler may have occluded oxide pores and prevented optimal adhesive/oxide interphase interlock, and there may have been competition of polyimide for calcium carbonate filler and for oxide. Average oxide thickness values of 65 to 410 nm did not affect bond strength; structural bonds were produced in all cases. CA/HF initial current density of 20 Amperes per square meter produced 33% stronger polysulfone bonds than 30 Amperes per square meter. Polysulfone microstructure may have been chemically degraded by the unnecessarily high fluoride concentration in the oxide from the higher current density. Lica® 44 titanate primer did not significantly influence bond strength or durability, except when unfilled polyetherimide was the adhesive. Polyphenylquinoxaline bond processing influenced bond strength. Structural bonds resulted for all the CA/HF anodization and process conditions described above. Single Iap bond fracture initiated in the adhesive (polymer) fillet. Fracture propagation in the bond overlap was through the polymer/anodic oxide interphase and/or cohesively in the polymer.