Anodically assisted chemical etching of conductive polymers and polymer composites

A process that improves the bond between a coating and an electrically conductive substrate comprising a polymer and/or a polymer composite, said process comprising the steps of:

• activating said outer surface of the electrically conductive substrate by subjecting at least part of an outer surface of said electrically conductive substrate to anodic polarization in an aqueous solution for a period of time in the range of 5 minutes to 30 minutes, while applying a current density to the electrically conductive substrate in the range of 0.05 to 0.1 A/cm2 and simultaneously chemically etching the electrically conductive substrate by oxidizing the electrically conductive substrate in the aqueous solution, and
• coating said electrically conductive substrate by applying a metallic or non-metallic coating to at least part of said activated outer surface of said electrically conductive substrate,
• wherein an adhesion strength between said coating and said electrically conductive substrate is at least 668 psi, as determined according to ASTM D4541-02 Method A-E, and
• said aqueous solution contains at least one etching compound selected from the group consisting of phosphoric acid, nitric acid, boric acid, sulfuric acid, chromic acid, hydrofluoric acid, a permanganate, sodium hypochloride, chlorine, bromine, peroxide, and ozone.