Analysis of Thermo-Mechanical Properties and Surface Features in Hot-Pressed Aluminium–PBT Interfaces

Dufera Bulto Gonfa; Devendra Kumar Sinha; Shimelis Lemma Beshahwured; Joginder Singh; Subhash Mishra; Shri Bhagwan

doi:10.5750/ijme.v168iA3(S).1962

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Published: Oct 7, 2026

DOI: https://doi.org/10.5750/ijme.v168iA3(S).1962

Keywords:

Shear strength Joining parameters Roughness measurements Height parameters

Dufera Bulto Gonfa

College of Mechanical, Chemical and Materials Engineering, Adama Science and Technology University, Ethiopia

Devendra Kumar Sinha

Lakshmi Narain College of Technology, Bhopal, Madhya Pradesh, India

Shimelis Lemma Beshahwured

College of Mechanical, Chemical and Materials Engineering, Adama Science and Technology University, Ethiopia

Joginder Singh

Rachna University, Faridabad, 121004, India

Subhash Mishra

IMS Engineering College, Ghaziabad, Uttar Pradesh, India

Shri Bhagwan

Teerthanker Mahaveer University, Moradabad, Uttar Pradesh, India

Abstract

Hybrid materials combining aluminum alloys with polymers are crucial for lightweight, durable, and multifunctional
components in automotive and aerospace industries, enhancing performance and cost efficiency. In this study,
AluminumMagnesiumSilicon alloy (AA6082) was joined to Polybutylene Terephthalate (PBT) using hot pressing. The
research examined optimum joining parameters, interfacial behavior, surface structure, and the effects of treatments and thermal conditions on bonding quality. Experiments applied controlled temperature, pressure, and time, alongside mechanical, chemical, and sandblasting treatments, before bonding ALPBT substrates reinforced with two glass fiber plies. Results showed heat input and pressure strongly influenced joint failure mode and shear force. Surface roughness measured with a 3D optical profilometer indicated Sa values of 3.64157 μm (sandblasted), 3.03447 μm (sandgrounded), and 0.422647 μm (untreated). Negative Ssk values revealed deep valleys, while Sku values above 3 indicated pronounced peaks. DMA, TGA, and DSC analyses confirmed that PBT’s melting point and glass transition temperature decreased after hot pressing as temperature increased.

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Vol. 168 No. A3(S) (2026): Special Issue - Smart and Sustainable Material for Marine Engineering Applications

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