Abstract: To address the challenge of efficiently and reliably connecting 7075 aluminum alloy with carbon fiber reinforced polyether ether ketone (CF/PEEK) composites in the manufacture of aerospace equipment. The aluminum alloy undergoes sandblasting, and various thicknesses of polyetherimide (PEI) thermoplastic layers are applied to its surface. This study aims to investigate the adhesion of sandblasted aluminum alloy to thermoplastic layers and the impact of different thicknesses of these layers on the quality of weld seams, strength, and cross-sectional morphology of welded joints. The results demonstratethat the rough structure created by sandblasting significantly improves the wettabilityand surface roughness of the aluminum alloy, thereby enhancing its adhesion to the thermoplastic layer. When the thickness of the thermoplastic layer is 0.4 mm, the strength of the welded joints after sandblasting significantly increases from 2.18 MPa to 18.48 MPa. In addition, the section failure mode of the welded joint is primarily attributed to the failure of the carbon fiber tear interlayer in the heating element.

Key words: 7075 aluminum alloy, carbon fiber reinforced polyether ether ketone composites, sandblasting, polyetherimide thermoplastic layers