Vol. 2, No. 7, 2007

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A cohesive zone finite element approach to model tensile cracks in thin film coatings

Srikant Nekkanty, Mark E. Walter and Rajiv Shivpuri

Vol. 2 (2007), No. 7, 1231–1247

A two-dimensional finite element model using cohesive zone elements was developed to predict cracking in thin film coating-interlayer-substrate systems that are subjected to tensile loading. The constitutive models were chosen to represent a metal carbide/diamond-like carbon composite coating with a titanium interlayer and a steel substrate. Material properties of the coating and interlayer along with the cohesive finite element parameters were varied to study effects on stress distributions and coating cracking. Stress distributions were highly nonuniform through the coating thickness. Thus the initiation and arrest of tensile cracks differed from what is predicted by simple shear-lay theory. Intercrack spacing distributions resulting from the variation of different parameters were quantified and compared with those from experiments.

thin film coatings, cohesive zone finite element modeling, tensile cracking, intercrack spacing
Received: 24 July 2006
Accepted: 20 February 2007
Published: 1 September 2007
Srikant Nekkanty
Department of Industrial, Welding and Systems Engineering
Ohio State University
Columbus, OH 43210
United States
Mark E. Walter
Department of Mechanical Engineering, E331 Scott Laboratory
Ohio State University
201 W. 19th Avenue
Columbus, OH 43210
United States
Rajiv Shivpuri
Department of Industrial, Welding and Systems Engineering
Ohio State University
Columbus, OH 43210
United States