Interface Strength, Damage and Fracture between Ceramic Films and Metallic Substrates

Abstract

Interface strength, damage and fracture properties between ceramic films and metallic substrates affect the service reliability of related parts. The films’ thickness, grain size and residual stress affect the interface properties and fracture behavior, thus related studies attract great attention. In this paper, the interface damage evolution and fracture behavior between ceramic films and metallic substrates were simulated by developing a three dimensional finite element model of alumina films on Ni substrates with cohesive elements in the interfaces. The interface fracture energy as a key parameter in the simulation was firstly determined based on its thermodynamic definition. The simulation results show the Mises stress distribution and damage evolution of the film/substrate structures during uniaxial tensile loading. Specially, when grain size of the films is in nanoscale, the interface strength increases obviously, agreeing with the previous experimental results. The effects of residual stress on interface properties was further simulated. The interface strength was found to decrease with increasing radial residual force and the axial residual pressure increases the interface strength. When the thickness of the films increases, the interface strength keeps a constant but the speed of interface damage becomes faster, that is, the thicker films show catastrophic fracture. The underlying mechanism of damage speed was analyzed. Understanding these size effects and the effects of residual stress is helpful to guide the design of related parts.

A Cohesive-Zone-Based Contact Mechanics Analysis of Delamination in Homogeneous and Layered Half-Spaces Subjected to Normal and Shear Surface Tractions

“…Long et al [25] used a CZM-FEM approach to investigate the failure characteristics of bimaterial systems in uniaxial tension and observed a transition from coating cracking to interface delamination with increasing coating thickness. Liang et al [26] performed a CZM-FEM analysis of damage and fracture at the interfaces of ceramic films and metal substrates under uniaxial tensile loading and reported a dependence of the interfacial strength on both the residual radial force and the axial pressure and a catastrophic failure for thicker films.…”