A review of theoretical analysis techniques for cracking and corrosive degradation of film-substrate systems

Nazir, Mian Hammad; Khan, Zulfiqar Ahmad

doi:10.1016/j.engfailanal.2016.11.010

Cited by 33 publications

(23 citation statements)

References 137 publications

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“…In terms of modelling these effects, there has been much literature—for example, see the theoretical review of thin film cracking 67 . The characteristic crack spacing λ of periodic cracks in a thin film having a thickness under uni-axial strain has been modelled by the following equation: 49 , 58 where is strain of the film — is the zero-strain length and is the length increase, —where is the elastic (Young’s) modulus of the film, is the Poisson coefficient of the film, and corresponds to the work of fracture of the film—having units of Jm −2 .…”

Section: Resultsmentioning

confidence: 99%

Cracking effects in squashable and stretchable thin metal films on PDMS for flexible microsystems and electronics

Baëtens¹,

Pallecchi²,

Thomy³

et al. 2018

Sci Rep

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Here, we study cracking of nanometre and sub-nanometre-thick metal lines (titanium, nickel, chromium, and gold) evaporated onto commercial polydimethylsiloxane (PDMS) substrates. Mechanical and electromechanical testing reveals potentially technologically useful effects by harnessing cracking. When the thin film metal lines are subjected to uniaxial longitudinal stretching, strain-induced cracks develop in the film. The regularity of the cracking is seen to depend on the applied longitudinal strain and film thickness—the findings suggest ordering and the possibility of creating metal mesas on flexible substrates without the necessity of lithography and etching. When the metal lines are aligned transversally to the direction of the applied strain, a Poisson effect-induced electrical ‘self-healing’ can be observed in the films. The Poisson effect causes process-induced cracks to short circuit, resulting in the lines being electrically conducting up to very high strains (~40%). Finally, cracking results in the observation of an enhanced transversal gauge factor which is ~50 times larger than the geometric gauge factor for continuous metal films—suggesting the possibility of high-sensitivity thin-film metal strain gauge flexible technology working up to high strains.

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Section: Resultsmentioning

confidence: 99%

Cracking effects in squashable and stretchable thin metal films on PDMS for flexible microsystems and electronics

Baëtens¹,

Pallecchi²,

Thomy³

et al. 2018

Sci Rep

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show abstract

“…The residual stresses in all the coatings were measured by XRD and Reuss model using the computer program, Stress [ 16 , 31 , 32 ], while the corrosion rate measurement was performed by EIS measurements using potentiostat setup. From Figure 4 it was established that the nano particle size affects both the residual stresses and the corrosion rate of nickel-based composite coatings.…”

Section: Methodsmentioning

confidence: 99%

Analyzing and Modelling the Corrosion Behavior of Ni/Al2O3, Ni/SiC, Ni/ZrO2 and Ni/Graphene Nanocomposite Coatings

et al. 2017

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A study has been presented on the effects of intrinsic mechanical parameters, such as surface stress, surface elastic modulus, surface porosity, permeability and grain size on the corrosion failure of nanocomposite coatings. A set of mechano-electrochemical equations was developed by combining the popular Butler–Volmer and Duhem expressions to analyze the direct influence of mechanical parameters on the electrochemical reactions in nanocomposite coatings. Nanocomposite coatings of Ni with Al2O3, SiC, ZrO2 and Graphene nanoparticles were studied as examples. The predictions showed that the corrosion rate of the nanocoatings increased with increasing grain size due to increase in surface stress, surface porosity and permeability of nanocoatings. A detailed experimental study was performed in which the nanocomposite coatings were subjected to an accelerated corrosion testing. The experimental results helped to develop and validate the equations by qualitative comparison between the experimental and predicted results showing good agreement between the two.

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“…The organic coatings are susceptible to numerous types of failure modes including micro-cracking within the coating surface which allows the corrosive species to diffuse into the coating-substrate interface to initiate corrosion damage [2]. According to recent experimental investigations, parameters including interfacial roughness, interfacial toughness, diffusion-induced stresses and residual stresses are considered to be responsible for micro-cracks and adhesion loss in protective coatings applied to metal structures [2][3][4][5][6][7][8][9][10][11][12]. Various maintenance activities are implemented to protect and repair the metal structures e.g.…”

Section: Introductionmentioning

confidence: 99%

Structural monitoring system for proactive detection of corrosion and coating failure

Latif

Khan

Stokes

2020

Sensors and Actuators A: Physical

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The performance and availability of high priority structures can be greatly affected by corrosion damage. The application of protective coatings, frequent inspections and scheduled based maintenance activities result in huge direct and indirect financial loss to organisations. The expeditious detection of coating failure and corrosion damage can result in precise and costeffective condition-based maintenance. Coating failure and corrosion phenomena are driven by complex multidisciplinary parameters according to extensive research findings in the literature. State-of-the-art prognostic models proposed in recent years incorporate complex multidisciplinary parameters, therefore a real-time prognostic monitoring system must acquire these complex parameters to allow accurate prediction. The work reported here covers the development of a realtime monitoring system using micro-sensors and includes the validation of the system through accelerated corrosion and coating failure testing. The system contains a remote terminal unit that includes a linear polarisation method for corrosion detection under the coating and a micro-strain gauge method for monitoring stress behaviour over the coating. The software at base station includes a graphical user interface and database to store parameters for further processing and failure prediction. The real-time monitoring system can be applied to remote, stationary and mobile assets to monitor the mechanical and chemical changes within coating-substrate systems.

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A review of theoretical analysis techniques for cracking and corrosive degradation of film-substrate systems

Cited by 33 publications

References 137 publications

Cracking effects in squashable and stretchable thin metal films on PDMS for flexible microsystems and electronics

Cracking effects in squashable and stretchable thin metal films on PDMS for flexible microsystems and electronics

Analyzing and Modelling the Corrosion Behavior of Ni/Al2O3, Ni/SiC, Ni/ZrO2 and Ni/Graphene Nanocomposite Coatings

Structural monitoring system for proactive detection of corrosion and coating failure

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