BCW Treatments Publishes Aluminium Bonding Research

BCW Treatments Manager Publishes Scientific Paper on Aluminium Bonding Innovation

We are proud to announce that Dr. Junia Cristina Avelar-Batista-Wilson, Technical & Quality Systems Manager at BCW Treatments, has co-authored a new scientific paper on advanced aluminium surface treatments.

Published on 8 October 2025 in the International Journal of Adhesion and Adhesives (accessible via ScienceDirect), this peer-reviewed paper investigates how sulphuric acid anodising and adhesive selection impact the strength of bonded aluminium joints.

The publication not only highlights key technical findings in adhesive bonding for aluminium alloy AA6060-T6 but also underscores BCW’s commitment to innovation and sustainability in surface treatment technology.

Innovative Research in Aluminium Surface Treatments

Adhesive bonding is increasingly critical in modern manufacturing, offering a way to join components without heavy fasteners or welding. Many automotive and aerospace manufacturers now rely on structural adhesives as a primary joining method to achieve robust, lightweight structures.

However, the highest-performing one-part epoxy adhesives typically require high-temperature curing (around 190 °C) in large ovens, a process that consumes significant energy and limits material compatibility.

Emerging cold-cure adhesives, which cure at lower temperatures (often near room temperature), promise to eliminate energy-intensive oven curing, reducing costs and thermal distortion.

The question and the focus of Dr. Avelar-Batista-Wilson’s research is how these cold-cure adhesives compare with traditional hot-cure systems in joint performance.

Methodology and Key Findings

In this study, anodised aluminium coupons were bonded using two different epoxy-based adhesives: one requiring a conventional hot cure and one formulated for low-temperature cold cure. The sulphuric acid anodising (SAA) surface treatment was chosen due to its proven ability to enhance adhesive bonding by increasing surface roughness and wettability.

The paper evaluates lap-shear strength for both adhesive systems to quantify performance differences.

Key Findings

• Hot-cure vs Cold-cure Performance:
  The hot-cure adhesive achieved higher lap-shear strength than the cold-cure adhesive under identical conditions, reflecting the cold-cure adhesive’s inherently lower bulk mechanical properties. While cold-cure systems offer processing and sustainability benefits, they currently deliver slightly lower bond strength than fully cured high-temperature epoxies.
• Importance of Surface Treatment:
  Both adhesives benefited from the SAA pretreatment, yielding strong bonds that meet typical structural requirements. Proper anodising was shown to be critical for durable adhesive joints, as it provides a surface that maximises adhesive effectiveness. Even the cold-cure adhesive achieved improved performance on anodised aluminium, underlining how BCW’s surface treatment expertise can help optimise new adhesive technologies.
• Guidance for Industry:
  By quantifying the performance gap between a hot-cure adhesive and a cold-cure alternative, the study provides valuable data for OEM engineers considering more sustainable bonding methods. The results demonstrate how design adjustments or process controls can enable lower-temperature adhesives to deliver strong, reliable bonds without compromising integrity.

Advancing the Science of Sustainable Manufacturing

Dr. Avelar-Batista-Wilson’s research exemplifies how BCW Treatments is pushing the boundaries of material science and sustainability in real-world applications.

“We are thrilled to share these findings with the industry, as they validate our approach to enhancing bonding of aluminium components through the right combination of surface preparation and adhesive technology,” said Dr. Junia Cristina Avelar-Batista-Wilson, Technical & Quality Systems Manager, BCW Treatments.

This work strengthens BCW’s technical leadership across key sectors including automotive, aerospace, defence, and EV battery systems, industries where aluminium bonding performance directly influences weight, safety, and sustainability targets.

Recognition of Excellence

This publication has also been provisionally selected for the “Best Researcher Award” by the Organising Committee of the International Phenomenological Research Awards, acknowledging the significance of Dr. Avelar-Batista-Wilson’s and Ben Robinson’s contribution to surface engineering and adhesive bonding research.

Driving Innovation Through Vertical Integration

At BCW, innovation isn’t an afterthought, it’s built into everything we do.

By combining scientific research, process engineering, and vertically integrated manufacturing, we deliver solutions that help OEMs and Tier 1 suppliers build the next generation of products, lighter, stronger, more cost-efficient, and more sustainable.

This accomplishment underscores our unique position as part of the BCW Group, where we unite research, technical expertise, and a relentless commitment to quality to drive excellence across the entire supply chain.

 Read the full paper on ScienceDirect: https://www.sciencedirect.com/science/article/abs/pii/S0143749625002404