Fracture and cavitation in a constrained thin metal layer under a scale effect in layered materials

Dislocation activities are confined within a thin metal layer. Therefore instead of continuum plasticity theory, individual dislocation activities are considered in order to analyse their effects on fracture, especially interface fracture. Three failure modes may occur in the thin ductile layer: interface fracture, metal fracture and metal cavitation. These failure modes are studied and the competition between them is examined. It seems that interface fracture occurs prior to metal fracture provided that the cohesive strengths of the interface and the metal are similar. In general, the fracture toughness of the thin layer will increase with increasing layer thickness. However, at a layer thickness of about 10 mm, the layer is more likely to fail by interface debonding, prior to any failure by ductile cavitation. Finally, using material and geometric parameters, a relation is given which determines the competition between crack fracture and cavity instability.