To improve the strength of the adhesive-bonded carbon fiber reinforced polymer (CFRP) joints, atmospheric pressure plasma treatment (APPT) was used to treat a CFRP substrate surface. This study investigated the effects of nozzle distance (i.e., the distance between plasma nozzle and CFRP substrate) and nozzle speed (i.e., the moving speed of plasma nozzle relative to CFRP substrate) of APPT on the lap-shear strength of adhesive-bonded CFRP joints. Results show that the lap-shear strength of plasma-treated CFRP joints increased to a peak value and then decreased as the nozzle distance increased, and the nozzle distance associated with the peaked joint strength depends on the applied nozzle speed. The lap-shear strength of plasma-treated adhesive-bonded CFRP joints reaches up to 31.6 MPa, compared to 8.6 MPa of the as-received adhesive-bonded CFRP joints. The surface morphology of plasma-treated CFRP substrates was investigated by scanning electron microscope observation, and the mechanism associated with the improved joint strength after applying APPT was revealed through surface chemistry analysis. It is found that APPT not only effectively removed the content of Si element and –CH₃ (i.e., the main compositions of release agent) from the as-received CFRP substrate surface, but also generated many polar groups (i.e., –NH₂, –OH, –COOH, etc.), which has a positive effect on increasing the wettability and interfacial bonding strength of CFRP substrates and consequently results in a significant improvement of lap-shear strength of plasma-treated CFRP joints. In addition, the result of differential scanning calorimetry (DSC) test shows that the surface temperature of CFRP substrate should not exceed 175.3 °C during APPT. In this study, an empirical model governing temperature, nozzle distance and nozzle speed was established to guide the selection of atmospheric pressure plasma treatment process parameters in industrial manufacture.

The epoxy adhesive-galvanized steel adhesive structure has been widely used in various industrial fields, but achieving high bonding strength and corrosion resistance is a challenge. This study examined the impact of surface oxides on the interfacial bonding performance of two types of galvanized steel with Zn–Al or Zn–Al–Mg coatings. Scanning electron microscopy and X-ray photoelectron spectroscopy analysis showed that the Zn–Al coating was covered by ZnO and Al₂O₃, while MgO was additionally found on the Zn–Al–Mg coating. Both coatings exhibited excellent adhesion in dry environments, but after 21 days of water soaking, the Zn–Al–Mg joint demonstrated better corrosion resistance than the Zn–Al joint. Numerical simulations revealed that metallic oxides of ZnO, Al₂O₃, and MgO had different adsorption preferences for the main components of the adhesive. The adhesion stress at the coating–adhesive interface was mainly due to hydrogen bonds and ionic interactions, and the theoretical adhesion stress of MgO adhesive system was higher than that of ZnO and Al₂O₃. The corrosion resistance of the Zn–Al–Mg adhesive interface was mainly due to the stronger corrosion resistance of the coating itself, and the lower water-related hydrogen bond content at the MgO adhesive interface. Understanding these bonding mechanisms can lead to the development of improved adhesive-galvanized steel structures with enhanced corrosion resistance.