Effects of Interlaminar Failure on the Scratch Damage of Automotive Coatings: Cohesive Zone Modeling

Abstract

Interlaminar failure caused by scratches is a common damage mode in automotive coatings and is considered the potential trigger for irreversible destruction, i.e., plowing. This work strives to numerically investigate the mechanisms responsible for the complex scratch behavior of an automotive coating system, considering the interfacial failure. A finite element model is developed by incorporating a large deformation cohesive zone model for scratch-induced debonding simulation, where the mass scaling technique is utilized to minimize computational burden while ensuring accuracy. The delamination phenomenon of the automotive coating is reproduced, and its effects on scratch damage behavior are analyzed. Accordingly, it is revealed that the interlaminar delamination would produce significant stress redistribution, which leads to brittle and ductile damage of the coating and consequently affects the formation of plowing. Eventually, parametric studies on the effects of interfacial properties are performed. They demonstrate that the shear strength and shear fracture energy dominate scratch-induced delamination.

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“…The interfaces in these materials play a significant role in determining their material properties. The cohesive zone model (CZM) is widely used to describe and analyze the damage mode of material interface during the failure process [32][33][34][35][36][37]. The CZM has proven to be highly effective in capturing the intricate interactions between different material phases and predicting the initiation and propagation of cracks, debonding, and other failure mechanisms.…”