Journal of Stress Analysis

Journal of Stress Analysis

Enhancing Adhesive Bonding Through Advanced Surface Preparation: A Comprehensive Review

Document Type : Review Paper

Authors
1 Narmak Tehran
2 3Automative Fluids and Structures Analysis Research Laboratory, School of Automotive Engineering, Iran University of since and technology, Tehran, Iran
10.22084/jrstan.2026.31902.1276
Abstract
Surface preparation plays a decisive role in the strength, reliability, and durability of adhesively bonded assemblies made of metals, polymers, and fiber-reinforced composites. This review critically examines conventional and advanced surface preparation strategies, with particular emphasis on laser surface texturing and bio-inspired patterns. The discussion focuses on how surface morphology, surface chemistry, surface energy, wettability, and mechanical interlocking govern adhesive joint performance under mechanical, hygrothermal, and cyclic loading conditions. Evidence is summarized from standardized mechanical tests, including single-lap shear, peel, wedge, and Mode I/II fracture tests, together with durability assessments, surface characterization, and failure analysis. Mechanical abrasion and anodizing remain practical baseline methods, while plasma and UV treatments offer clean activation routes for low-surface-energy substrates. Laser texturing enables controllable micro-/nano-scale features and hierarchical architectures that improve wetting, adhesive penetration, interfacial anchoring, and aging resistance. Bio-inspired patterns further provide promising routes for crack-path control and enhanced damage tolerance. Finally, this review highlights key selection criteria, including adherend/adhesive compatibility, target performance, environmental durability, cost, sustainability, and scalability, and identifies future research needs in parameter sensitivity, hybrid pretreatments, long-term aging, fatigue, and mixed-mode fracture.
Keywords


Articles in Press, Accepted Manuscript
Available Online from 22 September 2026