Pressure-sensitive ductile layers – I. Modeling the growth of extensive damage

Polymeric adhesives sandwiched between two elastic substrates are commonly found in multi-layers and IC packages. The non-elastic deformation and flow stress of such adhesive joints are highly pressure-sensitive. In this work, we study the effects of pressure-sensitivity, α, and plastic dilatancy, β, on void growth and coalescence ahead of a crack in ductile adhesive joints. To this end, a single layer of discrete voids is placed ahead of the crack in a pressure-sensitive dilatant adhesive sandwiched between two elastic substrates. The adhesive joint is subjected to small-scale yielding conditions. Using an associated flow rule (α = β), we show that pressure-sensitivity not only intensifies damage levels but also increases its spatial extent several fold. The damage level as well as its spatial extent is found to be even greater when a non-associated flow rule (β < α) is deployed. A reduction in the damage process zone’s thickness further increases the voiding activity in the adhesive, thereby resulting in brittle-like failure. This work also examines the fracture toughness trends using a material failure criterion for crack growth.