In recent years the direct-adhesion polymer metal hybrid (PMH) technology has been increasingly used
in replacing all-steel load-bearing structural components especially in automotive front-end modules.
This work investigates correlations between the surface topography of aluminum sheet, injection overmolding
process parameters and adhesion between polymer andmetal. To this end severalmold surfaces
were prepared by shot peening aluminum sheets. Adhesion wasmeasured using the shear test. Different
microscopy techniques were implemented: optical microscopy for statistical characterization of
adhesion at different process conditions, scanning electron and scanning probe for characterization of the
adhesion phenomenon at the micro- and nano-scale.