Numerical analysis of mesoscale surface roughening in a coated plate

In this work, a 3D numerical analysis of surface roughening in a coated material under uniaxial tension is performed. The results obtained suggest that the rough interface between coating and substrate is responsible for the formation of the roughened relief on the examined free surface. Stresses normal to the free surface are shown to appear near the coating–substrate interface and, acting from inside, give rise to the formation of ridges and valleys on the surface.

► Strain-induced surface roughening in a 3D coated plate is studied numerically.
► Rough interface is responsible for appearance of stress normal to the free surface.
► Internal stresses acting from inside give rise to free surface roughening.