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Gold films on an elastomeric substrate can be stretched and relaxed reversibly by tens of percent. The films initially form in two different structures, one continuous and the other containing tribranched microcracks. We have identified the mechanism of elastic stretchability in the films with microcracks. The metal, which is much stiffer than the elastomer, forms a percolating network. To accommodate the large elongation of the elastomeric substrate, the metal network twists and deflects out of the plane but remains bonded to the soft substrate. Consequently, the metal film experiences only small strains and deforms elastically without suffering fatigue.

In recent development of deformable electronics, it has been noticed that thin metal films often rupture at small tensile strains. Here we report experiments with Cu films deposited on polymeric substrates and show that the rupture strains of the metal films are sensitive to their adhesion to the substrates. Well-bonded Cu films can sustain strains up to 10% without appreciable cracks and up to 30% with discontinuous microcracks. By contrast, poorly bonded Cu films form channel cracks at strains about 2%. The cracks form by a mixture of strain localization and intergranular fracture. The films rupture at large strains when the localization is retarded by the adherent substrates.

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An experimental study on the criteria for failure of polymer melts in uniaxial extension: The test case of a polyisobutylene melt in different deformation regimes Many flexible electronic surfaces comprise inorganic films on organic substrates. Mechanical failure of such integrated structures of stiff and compliant materials poses a significant challenge. This letter studies the stretchability of metal films on elastomer substrates. Our experiment shows that, when stretched, elastomer-supported metal films rupture at strains larger than those reported for freestanding films. We use a finite element code to simulate the rupture process of metal films. A freestanding metal film ruptures by forming a single neck. By contrast, a metal film on an elastomer substrate may develop an array of necks before rupture. While the pre-rupture necks do not change the electrical conductance appreciably, they elongate the metal film, leading to a large overall rupture strain.