Structural composite with a polymeric surface forming method

A method for bonding a polymer material and a metal-containing substrate to produce combined components of mechanisms, the method comprising:

• providing a metal-containing substrate having a contact surface with a plurality of relief asperities having a surface density within the range of about 50 pcs/mm2 and 1000 pcs/mm2 and forming a plurality of protuberances and recesses with a cross-section within the range of about 20 μm and about 100 μm with at least one of the plurality of protuberances and recesses oriented at an angle of between about 45° and about 90° to the contact surface;
• measuring the geometric parameters of the plurality of relief asperities;
• applying polymer material in a molten state, at least partially, to the contact surface with a thickness of at least 10 μm to penetrate the plurality of relief asperities to form an external cover for the plurality of relief asperities that occupies and envelops free volumes of the plurality of protuberances and recesses to form a joint between the external cover and the metal-containing substrate;
• and
• providing heat dissipation from the joint to reduce the amount of thermal expansion thereof;
• wherein the heat dissipation produces a counterforce that prevents the separation or the displacement of the external cover and the metal-containing substrate when external mechanical force is applied thereto.