Laser Surface Microtexturing for Enhanced Adhesive Bonding in Steel–Polymer and Steel–Ceramic Joints

Featured Application: Laser-based surface microtexturing presented in this study can be applied to the manufacturing of hybrid metal–polymer and metal–ceramic assemblies used in lightweight structural components, industrial housings, and functional elements requiring reliable adhesive bonding. The approach enables improved joint performance without additional mechanical fasteners and is compatible with automated laser processing systems used in industrial production environments. Laser surface microtexturing has emerged as an effective approach for improving the performance of adhesive joints between dissimilar materials. In this study, the influence of laser-generated micrometric surface features on the mechanical behavior of hybrid adhesive joints was investigated for two material systems: structural steel bonded to polyamide (PA66) and structural steel bonded to technical ceramic (Al2O3). Single-lap joints were manufactured using a two-component epoxy adhesive with two nominal bond-line thicknesses (0.1 mm and 1.0 mm). Prior to bonding, selected surfaces were modified by ultrashort-pulse laser microtexturing, producing well-defined circular features with characteristic depths on the order of tens of micrometers. The resulting microstructures were characterized using optical and scanning electron microscopy, and their geometric parameters were quantified through profilometric measurements. Mechanical performance was evaluated under shear and bending loading conditions. The results demonstrate a substantial increase in joint strength for laser-microtextured surfaces compared with non-textured references for both material combinations. The effect of surface microtexturing was more pronounced than the influence of adhesive layer thickness within the investigated range. These findings confirm that laser-induced surface microtexturing is a versatile and application-oriented surface preparation method capable of enhancing the reliability of adhesive bonding in hybrid metal–polymer and metal–ceramic assemblies.