Interfacial cavitation

Cavitation has long been recognized as a crucial predictor, or precursor, to the ultimate failure of various materials, ranging from ductile metals to soft and biological materials. Traditionally, cavitation in solids is defined as an unstable expansion of a void or a defect within a material. The critical applied load needed to trigger this instability -- the critical pressure -- is a lengthscale independent material property and has been predicted by numerous theoretical studies for a breadth of constitutive models. While these studies usually assume that cavitation initiates from defects in the bulk of an otherwise homogeneous medium, an alternative and potentially more ubiquitous scenario can occur if the defects are found at interfaces between two distinct media within the body. Such interfaces are becoming increasingly common in modern materials with the use of multimaterial composites and layer-by-layer additive manufacturing methods. However, a criterion to determine the threshold for interfacial failure, in analogy to the bulk cavitation limit, has yet to be reported. In this work, we fill this gap. Our theoretical model captures a lengthscale independent limit for interfacial cavitation, and is shown to agree with our observations at two distinct lengthscales, via two different experimental systems. To further understand the competition between the two cavitation modes (bulk versus interface), we expand our investigation beyond the elastic response to understand the ensuing unstable propagation of delamination at the interface. A phase diagram summarizes these results, showing regimes in which interfacial failure becomes the dominant mechanism.

Pressurized interfacial failure of soft adhesives

Interfacial separation of soft, often viscoelastic, materials typically cause the onset of instabilities, such as cavitation and fingering. These instabilities complicate the pathways for interfacial separation, and hence hinder the quantitative characterization of bulk and interfacial contributions to soft material adhesion. To overcome these challenges, we developed a method termed pressurized interfacial failure (PIF), in which the interfacial separation is controlled by applying a positive pressure at the contact interface between a rigid, annular probe and a thin adhesive. We conducted experiments on model and commercially-available acrylic adhesives. Surprisingly, all the materials studied here fail by an inside-out growth of an interfacial cavity and show similar trends in the interrelationship between the cavity radius, applied pressure and change of contact force. In contrast, the force-displacement relationships of the same materials measured by conventional tack tests vary significantly. Accordingly, we conclude that the PIF method allows for controlling the interfacial failure mechanism. Furthermore, we have applied a linear elastic fracture mechanics framework and conducted finite element analysis to develop analytical models to calculate the critical energy release rate for interfacial separation, G_c. For model acrylic adhesives and commercially available adhesives, the values of G_c are similar to values determined by sphere-probe tack tests. Collectively, the herein introduced PIF method and analysis work provide a new foundation for quantitatively decoupling the interfacial and bulk contributions to soft polymer adhesion.

Mechanics of adhesives under annular confinement: internal pressure, force, and interfacial area

Closed annular adhesive interfaces are commonly found in nature as well as in many existing and developing technologies. Such contacts provide enhanced control of interfacial history by prescribing whether interfacial separation occurs at the outer or inner edge, and whether internal pressure affects the required force for separation. To facilitate the development of technologies involving annular contacts, we have experimentally measured the relationship between applied displacement, resulting force and internal pressure, and annular interface dimensions for the contact between a rigid annular probe and an adhesive layer with finite thickness. Experiments were validated by finite element analysis models, which were used to develop semi-empirical analytical relationships for the changes in contact compliance as a function of material properties and geometric constraints. Additionally, the change in internal pressure was modeled as a function of annular contact dimensions and adhesive layer material properties. This model predicts the critical volume where internal pressure changes alters critical force for separating an annular contact interface. The results discussed here provide a foundation for new experimental protocols for characterizing soft materials, including pressure-sensitive adhesives, as well as guidelines for designing annular interfacial materials with controlled separation histories.