In this study, the joining technique of two different materials such as polyvinyl chloride (PVC) and aluminum that can replace steel insertion in the PVC profile industry was investigated. The aim was to improve the interface structure for joining PVC and aluminum with different geometries on the aluminum surface. The effects of mechanical surface roughness were studied for the joining performance. Aluminum samples with mechanically deformed surfaces were prepared and joined with PVC strips. Lap-shear, interlaminar shear strength (ILSS), 3-Point (3P) bending, and coefficient of linear thermal expansion (CTE) tests were performed. Microstructural investigations were conducted with an optical microscope and scanning electron microscope. According to the results obtained, mechanical surface roughness on the aluminum improved the joining interface between PVC and aluminum. The side-punched and perforated samples achieved the best results in terms of geometrical variations on the aluminum surface. Improvement in surface roughness resulted in a 2-fold increase in lap-shear shear strength and 45% reduction in 3-point bending test results. Optical microscopy was performed on the interface layer, the cavity structures were examined. In the samples with good adhesion results, it was observed that the desired locking mechanism was formed in joined structures as a result of the abrasion on the metal surface and the filling of holes with PVC.
