Using　polymer-metal　hybrids　offers　a　promising　energy　conservation　and　emission　reduction　approach.　In　this　investigation,　nanoporous　structures　with　varying　pore　sizes　were　synthesized　on　the　surface　of　aluminum　(Al)　by　adjusting　the　oxidation　duration.　Then,　aluminum　was　bonded　with　polyformaldehyde　(POM)　using　a　hot　pressing　technique.　An　increase　in　nanopore　size　resulted　in　enhanced　surface　roughness　and　wettability　of　the　Al,　thereby　promoting　the　embedding　of　POM　into　the　Al　surface　and　subsequently　improving　the　mechanical　interlocking　capability　at　the　interface.　The　embedding　depth　of　POM　with　varying　pore　sizes　was　analyzed　using　atomic　force　microscopy　(AFM).　Additionally,　a　flow　model　of　POM　within　nanopores　was　developed　using　the　finite　element　method,　and　the　calculated　diffusion　depths　were　consistent　with　the　experimental　results.　The　embedding　depth　reached　2.38　μm　when　the　pore　size　was　approximately　100　nm,　at　which　point　the　interface　achieved　the　optimal　filling　ratio.　Furthermore,　the　interface　was　examined　using　X-ray　photoelectron　spectroscopy　(XPS)　and　density　functional　theory　(DFT),　revealing　the　presence　of　an　Al-O-C　chemical　bond.　The　maximum　joining　strength　of　the　POM-Al　hybrid　reached　42.56　MPa,　and　the　failure　mode　was　a　mixed　failure　mode　of　interfacial　failure　and　cohesive　failure.　In　summary,　these　results　are　crucial　for　further　designing　and　optimizing　polymer-metal　hybrids　prepared　using　anodic　oxidation.　©　2024　Elsevier　Ltd