Analysis of multiple cracks in thin coating on orthotropic substrate under mechanical and residual stresses

The analysis addresses a typical failure development pattern in thin films consisting of a system of multiple surface cracks leading to and branching along or near the interface between the film and the base material. The process is driven by thermal residual stresses and/or mechanical loading. Due to the high temperature gradients during the fabrication process, usually a net of surface cracks develops, which gives the appearance of a granular structure of the surface. A periodic array of parallel surface cracks is assumed. A “unit cell” or single cracked segment attached to the substrate is analyzed instead by assuming the channel cracks are spaced more or less uniformly and perfectly aligned in parallel in the transverse direction of the coating. The analysis is specialized to orthotropic and transversally isotropic materials. The problem is solved using FEM combined with the reciprocal theorem. Matched asymptotic procedure [Leguillon D, Sanchez-Palencia E. Computation of singular solutions in elliptic problems and elasticity. Paris: Masson; 1987; Vu-Quoc L, Tran VX. Singularity analysis and fracture energy-release rate for composites: piecewise homogenous-anisotropic materials. Comput Methods Appl Mech Engng 2006;195:5162–97] is used to derive the change of potential energy. Higher-order terms in the asymptotics are considered. The competition between penetration and debond for periodically distributed edge cracks especially near the critical value of the ratio of fracture spacing to the layer thickness is examined.