Patent Publication Number: US-2023146670-A1

Title: Adhesive bonded composite-to-metal hybrid vanes and method of manufacture

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of, and claims priority to, and the benefit of U.S. Non-Provisional application Ser. No. 17/185,010, entitled “ADHESIVE BONDED COMPOSITE-TO-METAL HYBRID VANES AND METHOD OF MANUFACTURE,” filed on Feb. 25, 2021. The &#39;010 application claims priority to, and the benefit of, U.S. Provisional Application No. 62/990,903, entitled “ADHESIVE BONDED COMPOSITE-TO-METAL HYBRID VANES AND METHOD OF MANUFACTURE,” filed on Mar. 17, 2020. All of which are hereby incorporated by reference in their entireties for all purposes. 
    
    
     FIELD OF THE DISCLOSURE 
     The present disclosure relates to the method of manufacturing composite-to-metal hybrid bonded structures comprising metal body, laser treated metal surface, composite body. 
     BACKGROUND OF THE DISCLOSURE 
     Composite-to-titanium adhesively bonded structures require high bond performance and consistent bond quality. Surface structures and surface chemistry on pre-bond metal substrates are important for adhesive bond performance and durability. An oxide layer with micro-level or nano-level open-pore structures is desirable to form strong bonding with aerospace-rated organic adhesives, primers or composite resin matrices. An oxide layer allows for the formation of chemical bond between metal substrate and organic adhesives/primers/composite resin matrices. High degree of open pore structures and increased micro-level roughness enhance the mechanical interlocking of adhesives/primers/composite resin matrices. Traditionally, abrasion, chemical etching and anodizing processes have been used as standard processes for metal substrates prior to bonding. However, bond quality from grit blast is often inconsistent, consequently risk in durability may become high. Etching and anodizing processes are wet chemistry batch processes and tend to use large quantities of hazard chemical solutions for immersion of entire parts. 
     SUMMARY OF THE DISCLOSURE 
     A method for surface treating a titanium alloy vane prior to adhesive bonding is disclosed herein. The method may comprise: determining, by a processor, a predetermined set laser path corresponding to a predefined geometric pattern; commanding, by the processor, a laser to apply a pulsed laser beam to a contact surface of the titanium alloy vane along the predefined geometric pattern, the pulsed laser beam configured to contact the contact surface at a substantially normal angle relative to the contact surface. 
     In various embodiments, the method may further comprise prior to the commanding, by the processor, coupling the laser to a computer numeric control (CNC) tool. The predetermined set laser path may be a three-dimensional path corresponding to the predefined geometric pattern of the contact surface, wherein the contact surface has a complex three-dimensional surface. The predefined geometric pattern may comprise at least one of a linear array pattern, a perpendicular crosshatch pattern, or a rotating linear array. A topography of the contact surface after applying the pulsed laser beam to the contact surface may be substantially more uniform relative to an alkaline etching surface treatment. Applying the pulsed laser beam to the contact surface may further comprise forming an open pore oxide structure on the contact surface. The laser may be configured to travel along a three-dimensional path and surface treat a complex three-dimensional surface. 
     A method of manufacturing a composite-to-metal hybrid vane is disclosed herein. The method may comprise: treating a surface of a vane with a pulsed laser, the vane comprising a titanium alloy; generating a porous oxide layer on a contact surface of the vane; infiltrating the porous oxide layer with at least one of an adhesive, primer, or composite resin matrix; and coupling a composite laminate to the vane. 
     In various embodiments, coupling the composite laminate to the titanium alloy may further comprise co-curing the composite laminate and the adhesive. In various embodiments, coupling the composite laminate to the titanium alloy may further comprise secondary bonding of the composite laminate with the adhesive. The method may further comprise applying the composite laminate to the adhesive prior to coupling the composite laminate to the vane. Applying the composite laminate to the adhesive may further comprise applying the composite laminate via resin transfer molding. Applying the composite laminate to the adhesive may further comprise applying the composite laminate via autoclave processing. Applying the composite laminate to the adhesive may further comprise applying the composite laminate via compression molding. 
     A composite-to-metal hybrid vane is disclosed herein. The composite-to-metal hybrid vane may comprise: a titanium alloy including a contact surface, the contact surface including an open pore oxide structure having a topography with a height between 5 nm and 2000 nm; an adhesive infiltrating the open pore oxide structure; and a composite laminate bonded to the titanium alloy. 
     In various embodiments, the topography of the contact surface may be substantially more uniform relative to an alkaline etching surface treatment. The open pore oxide structure may include a pore distance between 0.05 and 1 μm. The topography may include a plurality of linear arrays. Each linear array may further comprise a width less than 25 μm, and a spacing between each linear array is between 10-50 μm. The topography may include a perpendicular crosshatch pattern. 
     The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated otherwise. These features and elements as well as the operation thereof will become more apparent in light of the following description and the accompanying drawings. It should be understood, however, the following description and drawings are intended to be exemplary in nature and non-limiting. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in, and constitute a part of, this specification, illustrate various embodiments, and together with the description, serve to explain the principles of the disclosure. 
         FIG.  1    illustrates a cross-sectional view of an exemplary gas turbine engine, in accordance with various embodiments; 
         FIG.  2    illustrates a perspective view of a portion of a fan section of a gas turbine engine having a variable vane assembly configured for non-axisymmetric actuation, in accordance with various embodiments; 
         FIG.  3    illustrates a perspective, semi-exploded view of a fiber metal laminate, in accordance with various embodiments; 
         FIG.  4    illustrates a system of laser treating a substrate, in accordance with various embodiments; 
         FIGS.  5 A and  5 B  illustrate a front view and a top view of a substrate after laser treating, in accordance with various embodiments; 
         FIG.  6    illustrates a system for laser treating a vane, in accordance with various embodiments; 
         FIG.  7    illustrates a block diagram depicting a method for laser treating a vane, in accordance with various embodiments; 
         FIG.  8    illustrates a system for adhesively bonding a vane to a composite laminate, in accordance with various embodiments; and 
         FIG.  9    illustrates a pre-bonding surface treatment of a titanium component compared to a pre-bonding surface treatment of titanium via a laser surface treatment, in accordance with various embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     The detailed description of various embodiments herein makes reference to the accompanying drawings, which show various embodiments by way of illustration. While these various embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, it should be understood that other embodiments may be realized and that logical, chemical, electrical, and mechanical changes may be made without departing from the spirit and scope of the disclosure. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. 
     For example, the steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected, or the like may include permanent, removable, temporary, partial, full, and/or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. 
     For example, in the context of the present disclosure, methods, systems, and articles may find particular use in connection with gas turbine engines. However, various aspects of the disclosed embodiments may be adapted for optimized performance in a variety of engines or other applications. As such, numerous applications of the present disclosure may be realized. 
     In various embodiments and with reference to  FIG.  1   , a gas turbine engine  20  is provided. Gas turbine engine  20  may be a two-spool turbofan that generally incorporates a fan section  22 , a compressor section  24 , a combustor section  26  and a turbine section  28 . In operation, fan section  22  can drive fluid (e.g., air) along a bypass flow-path B while compressor section  24  can drive fluid along a core flow-path C for compression and communication into combustor section  26  then expansion through turbine section  28 . Although depicted as a turbofan gas turbine engine  20  herein, it should be understood that the concepts described herein are not limited to use with turbofans as the teachings may be applied to other types of turbine engines. 
     Gas turbine engine  20  may generally comprise a low speed spool  30  and a high speed spool  32  mounted for rotation about an engine central longitudinal axis A-A′ relative to an engine static structure  36  or engine case via several bearing systems  38 ,  38 - 1 , and  38 - 2 . Engine central longitudinal axis A-A′ is oriented in the z direction on the provided xyz axis. It should be understood that various bearing systems  38  at various locations may alternatively or additionally be provided, including for example, bearing system  38 , bearing system  38 - 1 , and bearing system  38 - 2 . 
     Low speed spool  30  may generally comprise an inner shaft  40  that interconnects a fan  42 , a low pressure compressor  44  and a low pressure turbine  46 . Inner shaft  40  may be connected to fan  42  through a geared architecture  48  that can drive fan  42  at a lower speed than low speed spool  30 . A fan case  34  may surround fan  42 . Geared architecture  48  may comprise a gear assembly  60  enclosed within a gear housing  62 . Gear assembly  60  couples inner shaft  40  to a rotating fan structure. High speed spool  32  may comprise an outer shaft  50  that interconnects a high pressure compressor  52  and high pressure turbine  54 . 
     A combustor  56  may be located between high pressure compressor  52  and high pressure turbine  54 . Inner shaft  40  and outer shaft  50  may be concentric and rotate via bearing systems  38  about the engine central longitudinal axis A-A′, which is collinear with their longitudinal axes. As used herein, a “high pressure” compressor or turbine experiences a higher pressure than a corresponding “low pressure” compressor or turbine. 
     The core airflow C may be compressed by low pressure compressor  44  then high pressure compressor  52 , mixed and burned with fuel in combustor  56 , then expanded over high pressure turbine  54  and low pressure turbine  46 . Turbines  46 ,  54  rotationally drive respective low speed spool  30  and high speed spool  32  in response to the expansion. 
     In various embodiments, the low pressure compressor  44 , the high pressure compressor  52 , the low pressure turbine  46 , and the high pressure turbine  54  may comprise one or more stages or sets of rotating blades and one or more stages or sets of vanes axially interspersed with the associated blade stages but non-rotating about engine central longitudinal axis A-A′. 
     With reference to  FIG.  2   , a forward (or inlet) section of fan  42  is depicted in greater detail. Fan  42  may include one or more rotor assemblies (stages)  102 . Rotor assemblies  102  may each comprise a plurality of blades  106  configured to rotate about engine central longitudinal axis A-A′. In various embodiments, a variable vane assembly  100  may be located at forward (or inlet) end  61  of fan case  34 . Stated differently, variable vane assembly  100  may be located forward of the forwardmost rotor assembly  102  of fan  42 . Variable vane assembly  100  may comprise a plurality of vanes  110  circumferentially spaced about engine central longitudinal axis A-A′. Vanes  110  direct fluid to blades  106 . As described in further detail below, vanes  110  may be variable, meaning that a stagger angle of, at least, a portion of vane  110  may be changed to distribute fluid flow evenly about engine central longitudinal axis A-A′. 
     A strut portion  112  of vanes  110  may be attached at a radially inward or (or first) end  130  to an inner diameter (ID) shroud  132 , and at a radially outward (or second) end  134  to fan case  34 . In various embodiments, fan case  34  may define a plurality of vane stem slots  140 . Vane stem slots  140  are circumferentially distributed around fan case  34 . Vane stems  120  may be located through vane stem slots  140 . Vanes stems  120  may protrude radially outward from the vane stem slots  140 . In various embodiments, a vane arm  142  may be coupled to each vane stem  120 . In various embodiments, a fastener  144  may couple vane arm  142  to vane stem  120 . Fastener  144  may comprise a screw, nut and bolt, clip, rivet, or other suitable attachment component. In various embodiments, the vane arm  142  extends approximately perpendicular to the vane stem  120  (e.g., in an axial direction). As used in the previous context, “approximately perpendicular” means±5° from perpendicular. Vane  110  may include a strut portion  112  and a flap portion  114 . Strut portion  112  may form a leading edge of vane  110 . Flap portion  114  may form a trailing edge of vane  110 . In accordance with various embodiments, flap portion  114  may be configured to pivot relative to strut portion  112 . 
     An airfoil, such as a vane  110 , may be comprised of a fiber metal laminate (“FML”). An FML is a structural material comprising layer(s) of composite material among layer(s) of metal. Such a structure allows the FML to have the strength properties of the metal comprised in the metal layers, along with the properties associated with the composite material layers, such as corrosion resistance, low density, elasticity, and/or fatigue, among others, that are more advantageous than those properties associated with metals. As used herein, unless stated otherwise, “metal” may refer to an elemental metal and/or a metal alloy. 
     With reference to  FIG.  3   , an FML  200  may comprise FML layers  205  in a stack  210 , comprising at least one metal layer and at least one composite material layer. In various embodiments, metal layers may alternate with composite material layers in stack  210  of FML layers  205 . For example, layers  212 ,  214 , and/or  216  may comprise metal, and layers  213  and  215  may comprise composite material. In various embodiments, the outer layers of FML  200 , layers  212  and  216  in  FIG.  2   , may comprise metal layers. In various embodiments, the outer layers of FML  200 , layers  212  and  216  in  FIG.  2   , may comprise composite material. In various embodiments, FML layers  205  may comprise a metal layer adjacent to another metal layer and/or a composite material layer adjacent to another composite metal layers. FML layers  205  of FML  200  may be arranged in any suitable arrangement, in addition to the arrangements described herein. 
     In various embodiments, one or more of FML layers  205  of FML  200  may be split, such as layer  213 . Layer  213 , for example, may comprise a first portion  213 A and a second portion  213 B. First portion  213 A may comprise the same or different material than second portion  213 B. For example, first portion  213 A may comprise metal while second portion  213 B may comprise composite material, or vice versa. Such a split configuration, such as layer  213 , may be referred to as a mixed layer. A mixed layer may comprise any number of different materials. In various embodiments, the layers adjacent to a mixed layer, such as layers  212  and  214  in  FIG.  2   , may be an FML layer  205  comprising a single material, or may be a mixed layer. Layers  212  and  214  may both comprise a metal layer, both comprise a composite material layer, or layers  212  may comprise a metal while  214  may comprise a composite material, or vice versa. 
     In various embodiments, an FML may comprise one or more stacks  210  of FML layers  205  comprising any suitable arrangement of FML layers  205 , for example, the arrangements described herein. 
     In various embodiments, a metal layer in FML  200  may comprise a metal or metal alloy. In various embodiments, a metal layer in FML  200  may comprise titanium metal, or the like. In various embodiments, a metal layer in FML  200  may comprise any titanium alloy, such as a titanium alloy comprising, by weight, 5.5-6.75 percent aluminum, 3.5-4.5 percent vanadium, and a maximum of 0.25 percent iron, 0.2 percent oxygen, 0.08 percent carbon, 0.015 percent hydrogen, 0.05 percent nitrogen, with the remainder being titanium, commonly known by the industry standard designation of Titanium 6Al-4V(e.g., that specified by the ASTM F1472 specification, also known as Grade 5 Titanium), and hereinafter referred to as “Titanium 6Al-4V.” In various embodiments, a metal layer in FML  200  may comprise any titanium alloy, for example, any alpha-beta titanium alloy, and titanium alloys known as Grades 6 through 38. 
     In various embodiments, FML layers  205  comprising composite material may comprise any composite material such as carbon fiber, fiber-reinforced polymer (e.g., fiber glass), para-aramid fiber, and/or aramid fiber. In various embodiments, in which an FML comprises metal layers comprising titanium and/or a titanium alloy, the composite material layers in the FML may comprise carbon fiber, such as graphite fiber. The combination of a metal layer comprising titanium and a composite material layer comprising carbon fiber may occur because titanium and carbon fiber do not form a galvanic cell, and therefore, galvanic corrosion may not occur. An FML comprising titanium and/or a titanium alloy and graphite fiber is commonly known in the industry as “TiGr.” In various embodiments, in which an FML comprises metal layers comprising aluminum and/or an aluminum alloy, the composite material layers in the FML may comprise fiber-reinforced polymer (e.g., fiber glass), para-aramid fiber, and/or aramid fiber. The combination of a metal layer comprising aluminum and a composite material layer comprising fiber glass and/or aramid fiber may occur because aluminum and fiber glass and/or aramid fiber do not form a galvanic cell, and therefore, galvanic corrosion may not occur. An FML comprising aluminum and/or an aluminum alloy and fiber glass is commonly known by the industry standard designation of “GLARE.” 
     Though FMLs described above include specific examples of metals, metal alloys, and/or composite materials, it would not be outside the scope of this disclosure to include any FML comprising any metal, metal alloy, and/or composite material, in any arrangement of layers. 
     In various embodiments, FML layers  205  and/or stacks  210  of FML layers  205  may be coupled together using an adhesive material or a composite resin matrix. In various embodiments, the adhesive material may comprise, for example, one or more epoxies, bismalemides, cyanate esters, or polyimides, and may be a supported or unsupported film and/or paste. A supported adhesive material may comprise a support comprised of nylon, polyester, fiberglass, or glass, which may be woven or non-woven. In various embodiments the adhesive material may comprise an amine cured, toughened epoxy resin system supplied with unidirectional and/or woven carbon or glass fibers. 
     Referring to  FIG.  4   , in accordance with various embodiments, a system of laser surface treatment of a substrate  400  is depicted comprising a substrate  405 , a first laser  410 , a first laser beam  420 , a second laser  440 , and a second laser beam  450 . The substrate  405  may comprise a metal, metal alloy, or any other suitable material. The substrate  405  may be a titanium alloy, such as Titanium 6Al-4V, or the like. 
     A substrate contact surface  406  of the substrate  405  may be treated in preparation for adhesive bonding or coupling to a second substrate. Titanium alloys may be surface treated directly with a first laser beam  420  that is transmitted from a first laser  410  and a second laser beam  450  that is transmitted from a second laser  440  and directed toward the substrate contact surface  406  of the substrate  405 . In various embodiments, the first laser  410  may comprise a fiber laser or a YAG Laser. In various embodiments, the first laser  410  and/or the second laser  440  may each comprise a YAG laser source or fiber laser source. In various embodiments, the first laser  410  and/or the second laser  440  may be operated in a pulsed mode having a wavelength, λ, of between 150 nm and 12,000 nm. In various embodiments, the laser may be operated in a pulsed mode having a wavelength, λ, of between 350 nm and 1100 nm, or between 100 nm and 400 nm. Any laser operation mode in the art may also be utilized, such as a continuous wave mode, or any other mode known in the art. In various embodiments, the first laser beam  420  and/or the second laser beam  450  shape and size are not critical to the process and can be any available combination, for representative purposes, the laser spot size may be round and about 25 to 50 μm in diameter with proper focus lens. In various embodiments, the single-pulse energy may range from 0.2 mJ and 1.0 mJ. In various embodiments, the pitch may be between 0.01 mm and 0.05 mm. In various embodiments, the laser speed, defined as the linear speed of the laser as it travels along a predetermined path, may be between 0.5 cm 2 /s and 50 cm 2 /min. In various embodiments, the laser speeds may be between 2 cm 2 /min and 35 cm 2 /min. 
     By varying the laser speed and the laser power, a desired topography on substrate contact surface  406  may be achieved. If the laser power is too high, the oxide formation and open-pore structures may be different, and an undesirable topography, such as solid oxide layer rather than open-pore structure or lack of oxide layer may be produced. If the laser power is too low, then the first laser beam  420  and/or the second laser beam  450  may not be strong enough to interact with metal surface to form the desirable oxide layer and generate open-pore topography of the substrate. Similarly, if the speed of the first laser beam  420  and/or the second laser beam  450  are too low, an undesirable topography is achieved because of overheat locally. Overheat can cause melting of a metal substrate beyond surface level. If the speed of the first laser beam  420  and/or the second laser beam  450  are too fast, an undesirable topography is achieved because insufficient energy cannot produce open-pore oxide structure. By treating the contact surface  406  of the substrate  405  with a first laser  410  and/or a second laser  440 , a pre-bond surface with highly increased surface area and high degree of open-pore oxide layer is formed on the substrate contact surface  406 . In various embodiments, substrate contact surface  506  may be flat, curved, rounded, concave, and/or convex. 
     In various embodiments, the first laser  410  and/or the second laser  440  may be coupled to a computer  430 . Computer  430  may be programmed to control the position and speed of the first laser  410  and/or the second laser  440 . Although shown as controlling the first laser  410  and/or the second laser  440 , in various embodiments, a computer may be coupled a robot/servomotor that is coupled to the substrate  405  and programmed to control the position of the substrate  405  while the first laser  410  and/or the second laser  440  remain stationary. In various embodiments, the first laser  410  and/or the second laser  440  may be moved manually during operation. In various embodiments, the substrate  405  may be moved manually during operation. In various embodiments, by having multiple lasers (e.g., first laser  410  and second laser  440 ), productivity may be enhanced during manufacturing. 
     Referring now to  FIGS.  5 A and  5 B , a side view and a top view of a topography comprising an overlapping linear array is depicted. In various embodiments, a substrate  805  may have a plurality of overlapping linear arrays  810  having a width W 4 . In various embodiments, the height H 4  may be between 5 nm to 2000 nm. In various embodiments, the height H 4  may be between 100 nm to 500 nm. In various embodiments, substrate contact surface  806  may be flat, curved, rounded, concave, and/or convex. In various embodiments, the width W 4  may be less than 40 μm. In various embodiments, the width W 4  may be less than 25 μm. In various embodiments, within each array there may be multiple peaks being spaced by a distance D 4 . In various embodiments, distance D 4  may be less than 5 μm. In various embodiments, the distance D 4  may be less than 1 μm. In various embodiments, each array  810  may have a thickness T 4 . The thickness T 4  may be between 0.05 to 1 μm. 
     Laser surface treatment, as described above, may provide excellent adhesive bond performance on titanium alloy surfaces. In various embodiments, adhesive bond performance of titanium alloys, after laser surface treatment, may show significant improvement in crack resistance. Laser surface treatment may also provide 100% cohesive failure mode of a substrate, resulting in desirable bond characteristics. 
     In various embodiments, laser treated titanium alloys may exhibit oxide layers formed at a macro-roughness and a micro-roughness. In various embodiments, the entire contact surface of a substrate may be treated. The oxide layers may form in the spacing to allow a nano-scale porous oxide layer to form on the substrate contact surface  406  and allow strong chemical interaction and additional mechanical interlocking to enhance adhesive bonding. In various embodiments, a primer, or adhesive, or composite resin matrix may fully infiltrate into the porous oxide layers. An additional benefit of laser surface treatment may be the removal of surface contaminants during the ablation process. In various embodiments, laser surface treatment, as described herein, may provide an automated and flexible surface treatment process to manufacture adhesively bonded structures, especially for airfoil contours. In various embodiments, laser treatment may replace alkaline etch process and/or avoid large quantities of chemicals in manufacturing. In various embodiments, a priming process may become optional during manufacturing. 
     Referring to  FIG.  6   , in accordance with various embodiments, a system  900  of laser surface treatment of a vane is depicted. The laser surface treatment system may comprise a computer numeric control (CNC) tool  950 , a laser  910 , and a computer  970 . Although illustrated with a single laser (e.g., laser  910 ), a plurality of lasers, as illustrated in  FIG.  3    is within the scope of this disclosure. The laser  910  and the CNC tool  950  may be electrically connected to the computer. In various embodiments, the system  900  may be used to laser surface treat a vane  905 . The vane  905  may comprise a contact surface  906 . In various embodiments, the vane  905  or airfoil attachment may be comprised of a titanium alloy, for example, Titanium 6Al-4V. 
     A pulsed laser beam  920  may be directed at contact surface  906 . The pulsed laser beam  920  may ablate portions of the contact surface  906  as described in the description when discussing  FIG.  3   . The pulsed laser beam  920  may be released from laser  910 , which may comprise any laser described herein in the description of the first laser  410  and/or the second laser  440  for  FIG.  4   . 
     In various embodiments, a laser  910  may be coupled to and/or coaxial with a CNC tool  950 . The CNC tool may be coupled to a computer  970 . Thus, in response to CNC tool  950  being programmed to center on a specific location, such as location to be ablated, the laser  910  may be focused on the specific location. A shroud  980  may surround laser  910  and CNC tool  950 . The shroud  980  may ensure that anyone operating the system  900  may be protected from the pulsed laser beam  920 . 
     The contact surface  906  may comprise a complex three-dimensional surface, such as a convex surface, a concave surface, a curved surface, or the like. In various embodiments, the contact surface  906  may comprise a pressure side of an airfoil. In various embodiments, the contact surface  906  may comprise a suction side of an airfoil. In various embodiments, the blade contact surface may comprise a leading edge of an airfoil. In various embodiments, the computer may be programmed to ensure that the laser  910  remains substantially normal to the contact surface  906  during operation. In various embodiments, substantially means plus or minus 10° in relation to the contact surface  906 . The computer may be programmed with a predefined geometric pattern for the contact surface  906 . In various embodiments, the predefined geometric pattern may comprise a linear array pattern, a perpendicular crosshatch pattern, a rotating linear array, a full surface linear array ( FIGS.  5 A and  5 B ) or any other pattern commonly known in the art. In various embodiments, the predefined geometric pattern may be applied to a portion of the contact surface  906 . The portion of the contact surface  906  may be a portion that may be adhesively bonded to a second component. In various embodiments, the topography of the contact surface  906  may be configured to be adhesively bonded to a second component. Examples of the second components including leading edge sheath, tip cap and other adhesively bonded attachments. The topography of contact surface  906  may also be also configured for other pre-bond surfaces of adhesively bonded structures used in structural guide vane, fan inlet case, imbedded bushing support and dissimilar material co-molding parts. 
       FIG.  7    illustrates a block diagram depicting a method  1000  of manufacturing a composite-metal hybrid vane, in accordance with various embodiments. With combined reference to  FIG.  4   , laser treating a substrate  405  comprising a titanium alloy, such as Titanium 6Al-4V under a first laser  410  and/or a second laser  440  (step  1002 ). In various embodiments, the substrate  105  may be disposed under a system comprising a CNC tool coupled to a laser, as depicted in  FIG.  6   . In various embodiments, the CNC tool may be coupled to a computer. 
     In various embodiments, a computer may be programmed to define a path for the laser to travel (step  1004 ). The path may correspond to a predefined geometric pattern corresponding to a desired topography of the contact surface. For example, the predefined geometric pattern may comprise a linear array pattern, a perpendicular crosshatch pattern, a rotating linear array, or any other pattern commonly known in the art. In various embodiments, the predefined pattern may be defined on a flat surface or a complex three-dimensional surface. 
     In various embodiments, a program may be run on the computer that applies a pulsed laser beam to a contact surface along the predefined geometric pattern (step  1006 ). The pulsed laser beam may be directed normal to the contact surface. In various embodiments, the operation may generate a highly open-pore oxide layer on the contact surface (step  1008 ). The highly porous oxide layer may comprise a topography corresponding to the predefined geometric pattern. 
     In various embodiments, the method may further comprise infiltrating the highly open-pore oxide layer with an adhesive (step  1010 ). In various embodiments, infiltrating the highly open-pore oxide layer may further include infiltrating the open pore oxide layer with or without primer. In various embodiments, the method may further comprise applying a composite laminate on an adhesive surface of the adhesive (step  1012 ). The step  1010  can be skipped and the step  1012  can be applied directly after the completion of the step  1008 . The composite laminate may be applied with resin transfer molding, autoclave, compression molding, or the like. 
     In various embodiments, the method may further comprise coupling the composite laminate to the vane (step  1014 ). The composite laminate may be coupled to the vane by co-curing the composite laminate and the adhesive or secondary bonding with the adhesive. 
     Referring to  FIG.  8   , in accordance with various embodiments, a system of bonded substrates  1100  is depicted comprising a first substrate  1105 , an adhesive  1110 , and a second substrate  1120 . The first substrate may comprise a titanium alloy, as disclosed previously herein, and the second substrate may comprise a composite laminate. A first substrate contact surface  1106  of the first substrate  1105  may be treated in preparation for bonding or coupling with the adhesive  1110  by a laser surface treatment, in accordance with various embodiments in this disclosure. Similarly, the second substrate contact surface  1121  of the second substrate  1120  may be laser treated in a similar manner as the first substrate contact surface  1106 . In various embodiments, only the first substrate contact surface  1106  may be treated. In various embodiments, by treating the first substrate contact surface  1106  with a laser, a highly open-pore oxide layer is formed on the first substrate contact surface  1106 . The highly open-pore oxide layer may then be infiltrated with an adhesive  1110 . 
     The adhesive  1110  may be disposed on the vane  905  and may comprise at least one nonmetallic material. The adhesive  1110  may be configured to bond two dissimilar, or similar, substrates or materials, the first substrate  1105  and the second substrate  1120 , and prevent galvanic corrosion from occurring between the first substrate  1105  and the second substrate  1120  by providing an isolation layer. As used herein, the term “isolating,” “isolation,” or the like, may refer to electrically insulating or electrical insulation, and/or completely or substantially blocking electrical conductivity and electrochemical communication between two or more materials and/or substrates. The adhesive  1110  may be coupled to the first substrate  1105  and second substrate  1120  after surface treatment of the first substrate contact surface  1106 , and the second substrate contact surface  1121 . The adhesive  1110  may comprise, for example, one or more epoxies, bismalemides, cyanate esters, or polyimides, and may be a supported or unsupported film and/or paste. A supported adhesive material may comprise a support comprised of nylon, polyester, fiberglass, or glass, which may be woven or non-woven. 
     Referring now to  FIG.  9   , a pre-bonding surface treatment of a titanium component compared to a pre-bonding surface treatment of titanium via a laser surface treatment, as disclosed herein, is illustrated in accordance with various embodiments. Conventional pre-bonding surface treatment includes pretreating a titanium component, such as a vane, with alkaline etching and primer prior to adhesive bonding. Alkaline etching may be a high cost batch process and/or include large quantities of chemicals, tight controls to minimize batch-to-batch variation, or the like. Alkaline etching may pose concerns for pretreatment consistency and/or impact bond quality. 
     As shown in  FIG.  9   , laser surface treatments of titanium alloys, as disclosed herein, may provide substantially more uniform topographical patterns on a contact surface. In this regard, the contact surface may include increased chemical and mechanical interlocking for bonding relative to typical alkaline etching surface treatments. An oxide layer formed from the laser surface treatment may allow for formation of chemical bonds between the titanium component and organic adhesives. 
     In that regard, methods disclosed herein may provide a more desirable miro-roughness than surfaces formed through alkaline etching. Moreover, the maximum peak height and maximum peak depth may be more precisely created and controlled related conventional means. In that regard, the more consistent micro-roughness profile may allow for bonds that may be more resistant to shear stress or other delaminating stresses, as well bonds that are more resistant to cracking. 
     Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosure. The scope of the disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. Different cross-hatching is used throughout the figures to denote different parts but not necessarily to denote the same or different materials. 
     Methods and systems for the bonding of dissimilar substrates are provided herein. In the detailed description herein, references to “one embodiment”, “an embodiment”, “various embodiments”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments. 
     Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112(f) unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.