The Mexican hat effect on the delamination buckling of a compressed thin film

Because of the interaction between film and substrate,the film buckling stress can vary significantly,depending on the delamination geometry,the film and substrate mechanical properties.The Mexican hat effect indicates such interaction.An analytical method is presented,and related dimensional analysis shows that a single dimensionless parameter can effectively evaluate the effect.     

Nonlinear analysis of compressed elastic thin films on elastic substrates: From wrinkling to buckle-delamination

Nonlinear buckling of elastic thin films on compliant substrates is studied by modeling and simulations to reveal the roles of pre-strain, elastic modulus ratio, and interfacial properties in morphological transition from wrinkles to buckle-delamination blisters. The model integrates an interfacial cohesive zone model with the Föppl–von Kármán plate theory and Green function method within the general framework of energy minimization. A kinetics approach is developed for numerical simulations. Subject to a uniaxial pre-strain, the numerical simulations confirm the analytically predicted critical conditions for onset of wrinkling and wrinkle-induced delamination, with which a phase diagram is constructed. It is found that, with increasing pre-strain, the equilibrium configuration evolves from flat to wrinkles, to concomitant wrinkles and buckle-delamination, and to an array of parallel straight blisters. The height and width of the buckle-delamination blisters can be approximately described by a set of scaling laws with respect to the pre-strain and interfacial toughness. Subject to an equi-biaxial pre-strain, the critical conditions are determined numerically to construct a similar phase diagram for the buckling modes. Moreover, by varying the pre-strain, modulus ratio, and interfacial toughness, a rich variety of equilibrium configurations are simulated, including straight blisters, and network blisters with or without wrinkles. These results provide considerable insight into diverse surface patterns in layered material systems as a result of the mechanical interactions between the film and the substrate through their interface, which suggests potential control parameters for designing specific surface patterns.     

Modeling of progressive delamination in a thin film driven by diffusion-induced stresses

A semi-analytical method based on the cohesive model has been developed to investigate the progressive growth of interface delamination in an axisymmetric thin film electrode driven by diffusion-induced stresses under the assumption that the electrode remains elastic during the Li-ion diffusion process. The evolutions of the cohesive zone and debonding zone with respect to charging time have been predicted. The cohesive zone propagates in an accelerating manner and the debonding zone advances in a slowing down manner. The key parameters that control the interfacial stresses and delamination have been identified from the obtained governing equations. And according to the discussions on the key parameters, design insights into the geometry, charging velocity and material properties of the electrode have been provided.     

Mixed-mode interfacial adhesive strength of a thin film on an anisotropic substrate

The mixed-mode interfacial adhesion strength between a gold (Au) thin film and an anisotropic passivated silicon (Si) substrate is measured using laser-induced stress wave loading. Test specimens are prepared by bonding a fused silica (FS) prism to the back side of a 〈1 0 0〉 Si substrate with a thin silicon nitride (Si_xN_y) passivation layer deposited on the top surface. A high-amplitude stress wave is developed by pulsed laser ablation of a sacrificial absorbing layer on one of the lateral surfaces of the FS prism. Due to the negative non-linear elastic properties of the FS, the compressive stress wave evolves into a decompression shock with fast fall time. Careful selection of the incident angle between the pulse and the FS/Si interface generates a mode-converted shear wave in refraction, subjecting the Si_xN_y/Au thin film interface to dynamic mixed-mode loading, sufficient to cause interfacial fracture. A detailed analysis of the anisotropic wave propagation combined with interferometric measurements of surface displacements enables calculation of the interfacial stresses developed under mixed-mode loading. The mixed-mode interfacial strength is compared to the interfacial strength measured under purely tensile loading.     

Finite width effect of thin-films buckling on compliant substrate: Experimental and theoretical studies

Buckling of stiff thin films on compliant substrates has many important applications ranging from stretchable electronics to precision metrology and sensors. Mechanics plays an indispensable role in the fundamental understanding of such systems. Some existing mechanics models assume plane-strain deformation, which do not agree with experimental observations for narrow thin films. Systematic experimental and analytical studies are presented in this paper for finite-width stiff thin films buckling on compliant substrates. Both experiments and analytical solution show that the buckling amplitude and wavelength increase with the film width. The analytical solution agrees very well with experiments and therefore provides valuable guide to the precise design and control of the buckling profile in many applications. The effect of film spacing is studied via the analytical solutions for two thin films and for periodic thin films.     

Controlled buckling of thin film on elastomeric substrate in large deformation

Electronic systems with large stretchability have many applications. A precisely controlled buckling strategy to increase the stretchability has been demonstrated by combining lithographically patterned surface bonding chemistry and a buckling process. The buckled geometry was assumed to have a sinusoidal form, which may result in errors to determine the strains in the film. A theoretical model is presented in this letter to study the mechanics of this type of thin film/substrate system by discarding the assumption of sinusoidal buckling geometry. It is shown that the previous model overestimates the deflection and curvature in the thin film. The results from the model agree well with finite element simulations and therefore provide design guidelines in many applications ranging from stretchable electronics to micro/nano scale surface patterning and precision metrology.     

A new failure mechanism in thin film by collaborative fracture and delamination: Interacting duos of cracks

When a thin film moderately adherent to a substrate is subjected to residual stress, the cooperation between fracture and delamination leads to unusual fracture patterns, such as spirals, alleys of crescents and various types of strips, all characterized by a robust characteristic length scale. We focus on the propagation of a duo of cracks: two fractures in the film connected by a delamination front and progressively detaching a strip. We show experimentally that the system selects an equilibrium width on the order of 25 times the thickness of the coating and independent of both fracture and adhesion energies. We investigate numerically the selection of the width and the condition for propagation by considering Griffith's criterion and the principle of local symmetry. In addition, we propose a simplified model based on the criterion of maximum of energy release rate, which provides insights of the physical mechanisms leading to these regular patterns, and predicts the effect of material properties on the selected width of the detaching strip.     

Behaviour of thick composite tubes considering of delamination

The present paper deals with plane finite element analysis of thick composite tubes. Thick composite tubes are commonly used in marine industry and in deep-water offshore applications. Two kinds of interlaminar delamination type defect in a thick walled cylinder subjected to external pressure were confronted; an annular or ring like delamination and a strip delamination. Two finite element models were developed to predict the strain energy release rate at the delamination fronts. In these models the effects of the processing history of the composite material in the form of a uniform thermal load were also included to simulate the state of the residual stress in the composite. The considered defects are studied by means of the effect of buckling, investigating the annular and the strip delamination buckling, and the subsequent loss of load carrying capacity of the delaminated region.     

Effect of geometrical imperfections on swelling-induced buckling patterns in gel films with a square lattice of holes

In this study, we investigate the effect of geometrical imperfections on swelling-induced buckling patterns in gel films with a square lattice of holes. Finite element analysis is performed using the inhomogeneous field theory of polymeric gels in equilibrium proposed by Hong et al. (2009). Periodic units consisting of 2 × 2 and 10 × 10 unit cells are analyzed under a generalized plane strain assumption. Geometrical imperfections are introduced using randomly oriented elliptical holes. The 2 × 2 unit cells show that the resulting buckling patterns are sensitive to imperfections; three different buckling patterns are obtained, and the most dominant one is the diamond plate pattern observed in experiments, which cannot be described using the model without imperfections. The 10 × 10 unit cells reveal that random imperfections are responsible for inducing homogeneous transformation into the diamond plate pattern. Furthermore, domain wall formation is simulated using a 10 × 10 unit cell model containing two elliptic holes.     

A new solution for the rotation-driven spreading of a thin fluid film

Lie groups are used to solve the equation governing the flow of a thin liquid film subject to centrifugal spreading and viscous resistance. A new implicit solution is found. It is shown how this relates to the previous known solutions for the spreading of an initially flat film, the steady state and a separable solution. New permissible forms for the film evolution are also studied, including solutions exhibiting finite time blow-up. Near the contact line, where the film height tends to zero, an approximate explicit solution is obtained which may be used to describe a film with any size contact angle.     

Modeling the interfacial effect on the yield strength and flow stress of thin metal films on substrates

It is shown in this paper that interfacial effects have a profound impact on the scale-dependent yield strength and strain hardening rates (flow stress) of metallic thin films on elastic substrates. This is achieved by developing a higher-order strain gradient plasticity theory based on the principle of virtual power and the laws of thermodynamics. This theory enforces microscopic boundary conditions at interfaces which relate a microtraction stress to the interfacial energy at the interface. It is shown that the film bulk length scale controls the size effect if a rigid interface is assumed whereas the interfacial length scale dominates if a compliant interface is assumed.     

A multi-scale modeling framework for instabilities of film/substrate systems

Spatial pattern formation in stiff thin films on soft substrates is investigated from a multi-scale point of view based on a technique of slowly varying Fourier coefficients. A general macroscopic modeling framework is developed and then a simplified macroscopic model is derived. The model incorporates Asymptotic Numerical Method (ANM) as a robust path-following technique to trace the post-buckling evolution path and to predict secondary bifurcations. The proposed multi-scale finite element framework allows sinusoidal and square checkerboard patterns as well as their bifurcation portraits to be described from a quantitative standpoint. Moreover, it provides an efficient way to compute large-scale instability problems with a significant reduction of computational cost compared to full models.     

Interfacial stress analysis and prediction of debonding for a thin plate bonded to a curved substrate

This paper focuses on the analytical and numerical modeling of the interface between a rigid substrate with simple constant curvature and a thin bonded plate. The interfacial behavior is modeled by independent cohesive laws in the normal and tangential directions, coupled with a mixed-mode fracture criterion. The newly developed analytical model determines the interfacial shear and normal stress distributions as functions of the substrate curvature, during the various behavioral stages of the interface prior to the initiation of debonding. The model is also able to predict the debonding load and the effective bond length. In the numerical model the interface is modeled by zero-thickness node-to-segment contact elements, in which both the geometrical relationships between the nodes of the discretized problem and the interface constitutive laws are suitably defined. Numerical results and comparisons between the predictions of the two models are presented.     

A computational model for the indentation and phase transformation of a martensitic thin film

We propose a computational model for a stress-induced martensitic phase transformation of a single-crystal thin film by indentation and its reverse transformation to austenite by heating. Our model utilizes a surface energy that allows sharp interfaces with finite energy and a penalty that forces the film to lie above the indenter and undergo a stress-induced austenite-to-martensite phase transformation. We introduce a method to nucleate the martensite-to-austenite phase transformation since in our model the film would otherwise remain in the martensitic phase in a local minimum of the energy.     

A computational homogenization approach for the yield design of periodic thin plates. Part I: Construction of the macroscopic strength criterion

The purpose of this paper is to propose numerical methods to determine the macroscopic bending strength criterion of periodically heterogeneous thin plates in the framework of yield design (or limit analysis) theory. The macroscopic strength criterion of the heterogeneous plate is obtained by solving an auxiliary yield design problem formulated on the unit cell, that is the elementary domain reproducing the plate strength properties by periodicity. In the present work, it is assumed that the plate thickness is small compared to the unit cell characteristic length, so that the unit cell can still be considered as a thin plate itself. Yield design static and kinematic approaches for solving the auxiliary problem are, therefore, formulated with a Love–Kirchhoff plate model. Finite elements consistent with this model are proposed to solve both approaches and it is shown that the corresponding optimization problems belong to the class of second-order cone programming (SOCP), for which very efficient solvers are available. Macroscopic strength criteria are computed for different type of heterogeneous plates (reinforced, perforated plates,…) by comparing the results of the static and the kinematic approaches. Information on the unit cell failure modes can also be obtained by representing the optimal failure mechanisms. In a companion paper, the so-obtained homogenized strength criteria will be used to compute ultimate loads of global plate structures.     

Effects of air-flow and evaporation on the development of thin liquid film over a rotating annular disk

Axisymmetric flow of thin pure liquid film on a spinning horizontal annular disk is studied under the action of air shear at the liquid–air interface and evaporation. The non-linear evolution equation that is obtained by singular perturbation method is solved analytically, for small Reynolds number, by using the method of characteristic and numerically by the use of Newton–Kantorovich method for any Reynolds number. Font breakdown time and its location from the center of the disk is predicted both by analytically and numerically. The result shows that the thinning of the initial film increases as air stress increase, same result is also escalated in presence of evaporation.     

Micron-scale channel formation by the release and bond-back of pre-stressed thin films: A finite element analysis

Buckling of thin films on a rigid substrate during use or fabrication is a well-known but unwanted phenomenon. However, this phenomenon can also be exploited to generate well-controlled patterns at the micro and nano-scale. These patterned surfaces find various technological applications such as optical gratings or micro/nano-fluidic channels. In this article, we present a numerical model that accounts for the buckling-up of pre-strained thin films by a reduction of the interface toughness and the subsequent bond-back. Channels are formed whose dimensions can be controlled by tuning the film dimensions, film thickness and stiffness, the eigenstrain in the film and the cohesive interface energy between the film and the substrate. We will show how the buckling-up and draping back processes can be captured in terms of a limited set of dimensionless parameters, providing quantitative insight on how these parameters should be tuned to generate a specified channel geometry.     

A comparative analysis of numerical approaches to the mechanics of elastic sheets

Numerically simulating deformations in thin elastic sheets is a challenging problem in computational mechanics due to destabilizing compressive stresses that result in wrinkling. Determining the location, structure, and evolution of wrinkles in these problems has important implications in design and is an area of increasing interest in the fields of physics and engineering. In this work, several numerical approaches previously proposed to model equilibrium deformations in thin elastic sheets are compared. These include standard finite element-based static post-buckling approaches as well as a recently proposed method based on dynamic relaxation, which are applied to the problem of an annular sheet with opposed tractions where wrinkling is a key feature. Numerical solutions are compared to analytic predictions of the ground state, enabling a quantitative evaluation of the predictive power of the various methods. Results indicate that static finite element approaches produce local minima that are highly sensitive to initial imperfections, relying on a priori knowledge of the equilibrium wrinkling pattern to generate optimal results. In contrast, dynamic relaxation is much less sensitive to initial imperfections and can generate low-energy solutions for a wide variety of loading conditions without requiring knowledge of the equilibrium solution beforehand.