FEM Modeling of In-Plane Stress Distribution in Thick Brittle Coatings/Films on Ductile Substrates Subjected to Tensile Stress to Determine Interfacial Strength

The ceramic-metal interface is present in various material structures and devices that are vulnerable to failures, like cracking, which are typically due to their incompatible properties, e.g., thermal expansion mismatch. In failure of these multilayer systems, interfacial shear strength is a good measure of the robustness of interfaces, especially for planar films. There is a widely-used shear lag model and method by Agrawal and Raj to analyse and measure the interfacial shear strength of thin brittle film on ductile substrates. The use of this classical model for a type of polymer derived ceramic coatings (thickness ~18 μm) on steel substrate leads to high values of interfacial shear strength. Here, we present finite element simulations for such a coating system when it is subjected to in-plane tension. Results show that the in-plane stresses in the coating are non-uniform, i.e., varying across the thickness of the film. Therefore, they do not meet one of the basic assumptions of the classical model: uniform in-plane stress. Furthermore, effects of three significant parameters, film thickness, crack spacing, and Young’s modulus, on the in-plane stress distribution have also been investigated. ‘Thickness-averaged In-plane Stress’ (TIS), a new failure criterion, is proposed for estimating the interfacial shear strength, which leads to a more realistic estimation of the tensile strength and interfacial shear strength of thick brittle films/coatings on ductile substrates.

Adhesion of Oxides Grown in Supercritical Water on Selected Austenitic and Ferritic/Martensitic Alloys

A series of austenitic alloys (800H, H214, I625, 310S, and 347) with different surface finishes were exposed to supercritical water (SCW) at 550 °C and 2.5 × 107 Pa for 120 h, 260 h, and 450 h in a static autoclave with an initial level of dissolved oxygen of 8 ppm. Indentation with a hardness indenter was used for assessment of oxide adhesion. This was compared with the results of a similar test on SCW-oxidized ferritic alloys. Delamination in all the tested ferritic alloys was insufficient for quantification of the results but allowed for qualitative comparison within this group. In the set of austenitic alloys, oxide on stainless steel (SS) 347 exfoliated during cooling from 550 °C, and from the remaining four alloys, only oxide on H214 delaminated, which made the qualitative comparison across the whole group impossible. Energy dispersive X-ray spectroscopy (EDX) revealed that under delaminated external Cr2O3 on H214 alloy, there was a submicron thick layer of Al-rich oxide. To investigate a possible oxide spallation on austenitic samples during exposure, mass loss obtained through descaling was compared with mass gain due to SCW exposure. The results indicated that the applied descaling procedure did not, in most cases, fully remove the scale. Apart from one case (SS 347 with alumina surface finish), there was no clear indication of oxide spallation.

Quantitative Modeling and Measurement of Copper Thin Film Adhesion

Numerous mechanisms have been identified as fundamental to the adhesion of thin metallic films. The primary mechanism is the thermodynamic work of adhesion of the interface, which in its most basic description is the difference between the surface energies of the two materials and that of the interface. This quantity is often described as leveraging the contributions of other mechanisms. One of the more important mechanisms is that of plasticity occurring in a process zone in the vicinity of the delamination boundary. A quantitative model to characterize the contributions of plastic energy dissipation has been developed and used to rationalize experimental adhesion assessments. This model incorporates the functional dependence of the film thickness and constitutive properties. Orders of magnitude increases in the practical work of adhesion were both observed and predicted. Experimentally, the films used for model comparison were sputter-deposited copper ranging from 40 to 3300 nm in thickness, with and without a thin 10 nm Ti underlayer. Nanoindentation induced delamination of the Cu from SiO2/Si wafers were evaluated in the context of composite laminate theory to determine adhesion energies ranging from 0.6 to 100 J/m2 for bare Cu and from 4 to 110 J/m2 for Cu with the Ti underlayer.

On radial crack and half-penny crack induced by Vickers indentation

Based on the stress fields formed upon Vickers indentation, the radial crack and half-penny crack systems are analysed separately using finite-element analyses. The crack length is correlated with the stress intensity factor (SIF) at the crack front and material elastoplastic properties via explicit relationships, from which a reverse analysis can be carried out such that the critical SIF (fracture toughness) can be readily derived once the crack length is measured. The proposed technique is validated by comparing with experimental data in the literature as well as parallel experiments of Vickers indentation-induced cracking.

Formation of the dentino-enamel interface in enamelysin (MMP-20)-deficient mouse incisors

An anomalous dentino-enamel junction (DEJ), manifested by delamination of the enamel layer, was reported in enamelysin [matrix metalloproteinase-20 (MMP-20)] knockout (KO) mice. To better understand the possible role of MMP-20 in the formation of the DEJ, we performed transmission electron microscopy (TEM) studies of the DEJ at early stages of tooth morphogenesis in KO mice. Our TEM analysis revealed that in the incisors from KO mice the mantle dentin is hypomineralized at the onset of enamel mineralization. At this early stage, TEM revealed no apparent differences in nascent aprismatic enamel between the KO mice and the controls. Hypomineralized mantle dentin was also observed in the incisors from KO mice, as assessed by back-scattered SEM at the secretory and early maturation stages, but not in the late-maturation stage, suggesting that the mineralization of mantle dentin is not completely arrested, but rather postponed. Histological studies indicate that the organic content in the initial enamel layer remains very high throughout amelogenesis. These results imply that MMP-20 is involved in the regulation of mineralization in mantle dentin and demonstrate the complex nature of DEJ formation. They also suggest that the structural and functional properties of the DEJ are determined during the initial mineralization stages.

Interfacial Fracture Toughness Measurement of Thick Ceramic Coatings by Indentation

The basic requirement for the use of a ceramic coating is sufficient adhesion to its substrate. A measure of the adhesive properties of a coating is the interfacial fracture toughness. The test method applicable for interfacial fracture toughness measurements depends on the mechanical properties of the material system and the geometry of the test piece. In this work, indentation methods have been evaluated for the estimation of the fracture toughness of ceramic thermal barrier coatings on metallic substrates. Coatings of 100 to 300 µm thickness were applied by electron beam – physical vapour deposition. The performed test types were Vickers indentation at the interface of polished cross sections of the coating system and Rockwell indentation with a brale C indenter, penetrating the coating perpendicular to the surface. Both tests generate delamination, in which the delamination crack length corresponds to the interfacial fracture toughness. Fracture surfaces and cross sections of the fractured coatings were investigated by optical and scanning electron microscope. Determined fracture toughness values are discussed with respect to the loading conditions in the test and the fracture process – i.e. interaction between indenter and coating system and the crack propagation path.