A combination of mechanical and chemical treatments was utilized to modify the surface textures of copper and duralumin inserts in order to enhance the adhesion at the metal–polymer interface and provide an adhesive joint with a high loadbearing capacity. Pretreatment of the surfaces with sandblasting was followed by etching with various chemical mixtures. The resulting surface textures were evaluated with a scanning electron microscope (SEM) and an optical confocal microscope. Surface geometry parameters (Sa, Sz, and Sdr) were measured and their relationships to the adhesion joint strength were studied. It was found that the virgin and purely mechanically treated inserts resulted in joints with poor loadbearing capacity, while a hundredfold (duralumin) and ninetyfold (copper) increase in the force to break was observed for some combinations of mechanical and chemical treatments. It was determined that the critical factor is overcoming a certain surface roughness threshold with the mechanical pretreatment to maximize the potential of the mechanical/chemical approach for the particular combination of material and etchant.

This study investigates the impact of internal muffler geometry on flow-related dissipation characteristics potentially relevant to acoustic behavior using steady-state Computational Fluid Dynamics (CFD) simulations. Four variants were analyzed: an empty tube, considered to be a baseline model, a three-chamber baffle system, a single spiral channel, and a complex multi-channel insert manufacturable only via advanced additive technologies. Simulations were conducted in SimScale using a compressible flow model with the k-ω SST turbulence formulation. Key outputs included static pressure distribution and turbulent kinetic energy (TKE), both of which were evaluated as qualitative surrogate indicators associated with flow-induced energy dissipation phenomena. The results indicate that geometries incorporating spiral features modify flow redistribution patterns, pressure gradients and localized turbulence intensity, suggesting potential applicability for future acoustic optimization studies. The study highlights how additive manufacturing enables the integration of geometrically complex internal structures otherwise unattainable through conventional methods. By comparing pressure drop and TKE patterns with internal design features, the research offers a preliminary CFD-based framework for geometry screening and conceptual evaluation of muffler insert designs for automotive exhaust systems. This approach provides computational support for rapid comparative assessment prior to experimental validation and detailed acoustic analysis.