Joints that connect
thermoplastic polymer matrices (TPMs) and metals,
which are obtained by comolding, are of growing importance in numerous
applications. The overall performance of these constructs is strongly
impacted by the TPM–metal interfacial strength, which can be
tuned by tailoring the surface chemistry of the metal prior to the
comolding process. In the present work, a model TPM–metal system
consisting of poly(methyl methacrylate) (PMMA) and titanium is used
to prepare comolded joints. The interfacial adhesion is quantified
by wire pullout experiments. Pullout tests prior to and following
surface modification are performed and analyzed. Unmodified wires
show poor interfacial strength, with a work of adhesion (
G
a
) value of 3.8 J m
–2
. To enhance interfacial
adhesion, a biomimetic polydopamine (PDA) layer is first deposited
on titanium followed by a second layer of a poly(methyl methacrylate-
co
-methacrylic acid) (P(MMA-
co
-MAA)) copolymer
prior to comolding. During processing, the MAA moieties of the copolymer
thermally react with PDA, forming amide bonds, while MMA promotes
the formation of secondary bonds and molecular interdigitation with
the PMMA matrix. Control testing reveals that neither PDA nor the
copolymer provides a substantial increase in adhesion. However, when
used in combination, a significant increase in adhesion is detected.
This observation indicates a pronounced synergistic effect between
the two layers that strengthens the PMMA-titanium bonding. Enhanced
adhesion is optimized by tuning the MMA-to-MAA ratio of the copolymer,
which shows a maximum at a 24% MAA content and a greatly increased
G
a
value of 155 J m
–2
; this
value corresponds to a 40-fold increase. Further growth in the
G
a
values at higher MAA contents is hindered
by the thermal cross-linking of MAA; MAA contents above 24% restrict
the formation of secondary bonds and molecular interdigitation with
the PMMA chains. Our results provide new design principles to produce
thermoplastic–metal comolded joints with strong interfaces.