Combinatorial investigations of interfacial failure

Conventional measurements of interfacial strength focus on a single variable, whereas many variables couple nontrivially and simultaneously to define this property. We present a combinatorial methodology that allows the effects of multivariable environments on interfacial strength to be investigated in a high‐throughput, parallel, and quantitative manner. This technique is largely based on the theory of Johnson, Kendall, and Roberts that quantifies adhesion through the contact and separation of a spherical lens and flat substrate. For our experiments, we fabricated a combinatorial library consisting of a two‐dimensional array of spherical caps and a complementary substrate. The array of spherical caps was brought into contact and subsequently separated from the substrate, whereas the relative displacement and contact area of the individual lenses were recorded. With gradient library‐fabrication methods, two adhesion‐controlling parameters can be continuously varied along the orthogonal axes of the array. In this manner, each lens quantifies the interfacial strength at a unique point in parameter space. We demonstrate this multilens contact‐adhesion test by measuring the effect of temperature and coating thickness on the self‐adhesion of polystyrene thin films. © 2003 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 41: 883–891, 2003