The adhesion performance of bis-1,2-(triethoxysilyl)ethane (BTSE) coatings on high-purity aluminum surfaces, which have been subjected to a Forest Products Laboratory (FPL) pre-treatment for different times, has been assessed with secondary-ion mass spectrometry (SIMS), X-ray photoelectron spectroscopy (XPS) and scanning electron microscopy (SEM). After coating, SIMS measurement of the ratio of peak intensities at 71 to 70 amu is used to identify the direct Al-O-Si bonding. The overall strength of the silane adhesion is assessed by comparing measurements of the Si 2p signals before and after application of an ultrasonic rinse to the coated sample. For the shorter FPL pre-treatment times (<10 min), substantial BTSE adsorption occurs on less-firmly anchored parts of the oxide which can be removed by the sonication test. The optimal adhesive bonding is indicated by these more microscopic studies to occur with the pre-treatments in the 10-25 min range, and this is in close correspondence with the normal FPL recipe that has been identified by performance in macroscopic tests. Pre-treatments longer than 25 min modify the surface topography further and give less direct Al-O-Si bonding, although the total BTSE adsorption is essentially constant and the adhesion remains strong enough to survive the sonication test. (C) 2003 Elsevier B.V. All rights reserved.