New Method to Distinguish Adhesion and Cohesion Stresses in Metal/Polymer Composites

Abstract This study aims at presenting a new analysis method for adhesive (interfacial) and cohesive (bulk) failures in aluminum (Al) and high-density polyethylene (HDPE) sandwich composites. The samples were submitted to tensile strength tests, according to ASTM C297 so as to obtain the pull-off stresses. The delaminated aluminum surfaces were analyzed with SEM/EDS (Scanning Electronic Microscopy with Energy Dispersive Scanning). The images were calculated using a genetic algorithm (GA), where the areas with cohesive and adhesive failures were identified by the presence or absence of organic compounds. The proposed method also uses the data from the pull-off tests to determine the stress values of adhesion and cohesion separately. Applying the new method, the mean stress of cohesion was 4.17 MPa, and for adhesion it was 0.57 MPa. Thus, it was possible to distinguish and calculate the failure stresses applied to metal/polymer composites.