Experimental-numerical failure analysis of the c-Al0.66Ti0.34N-M2 steel system applying instrumented indentation and extended finite element method

An experimental-numerical methodology for failure analysis of the c-Al0.66Ti0.34N/Interface/M2 steel coating system is proposed here. This Al0.66Ti0.34N coating was deposited by the arc-PVD technique. The values of the elastic modulus, the fracture energy release rate and the nano-hardness of the coating were obtained by nanoindentation. Normal and shear stress limits of the interface, as well as the adhesive and cohesive critical loads, were measured with the scratch test method. A finite element analysis, using the experimental mechanical properties, was carried out to understand the relationship between the irreversible work vs. depth curve and the mechanical failure evolution of the coating-substrate system, associating the pop-in with nucleation, crack growth and cracking pattern. Extended finite element method (XFEM) was applied for modeling of the mechanical behavior of the coating; the cohesive zones approach was applied for modeling the interface and the Ramberg-Osgood law for modeling the substrate. This approach proposes an experimental-numerical methodology for failure analysis of hard coatings (monolithic body) allowing to calculate fracture energy of the coating material and to model cracking patterns caused by contact mechanics. This work is the first step to answer questions about multi-scale approaches for multi-functional multi-layer coatings to push their enhancements and further applications.