Influence of Geometry on Interface Fracture Energy Measurements of Thermal Spray Coatings

Saim Abbas; Sanjay Sampath; Sudhanshu Mallick; B.  Nagamani Jaya

doi:10.1111/ffe.70054

Influence of Geometry on Interface Fracture Energy Measurements of Thermal Spray Coatings

Saim Abbas
, Sanjay Sampath
, Sudhanshu Mallick
, B. Nagamani Jaya

Materials Science and Engineering

Indian Institute of Technology Bombay

Research output: Contribution to journal › Article › peer-review

Abstract

Two novel bending-based interface fracture energy measurement techniques, the modified clamped beam and the modified cantilever, are compared on a model system consisting of air plasma–sprayed alumina over mild steel. Multiple values of interface energies are obtained on the same sample using digital image correlation (DIC)–based crack opening displacement (COD) measurements, converting both these techniques into high throughput. The mean and standard deviation in interface fracture energy (G_C) are found to be geometry dependent, with the modified clamped beam yielding a G_C of 56 ± 16 J/m², while the modified cantilever results in a G_C of 89 ± 5 J/m². The role of the phase angle and stress state on G_C and the resulting spread in the data is discussed. The advantages and limitations of the two geometries are contextualized for testing a variety of thermal spray coating/substrate combinations and other ceramic/metal interfaces.

Original language	English
Pages (from-to)	4541-4551
Number of pages	11
Journal	Fatigue and Fracture of Engineering Materials and Structures
Volume	48
Issue number	11
DOIs	https://doi.org/10.1111/ffe.70054
State	Published - Nov 2025

Keywords

interface fracture energy
modified cantilever
modified clamped beam
phase angle
thermal spray coatings

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10.1111/ffe.70054

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title = "Influence of Geometry on Interface Fracture Energy Measurements of Thermal Spray Coatings",

abstract = "Two novel bending-based interface fracture energy measurement techniques, the modified clamped beam and the modified cantilever, are compared on a model system consisting of air plasma–sprayed alumina over mild steel. Multiple values of interface energies are obtained on the same sample using digital image correlation (DIC)–based crack opening displacement (COD) measurements, converting both these techniques into high throughput. The mean and standard deviation in interface fracture energy (GC) are found to be geometry dependent, with the modified clamped beam yielding a GC of 56 ± 16 J/m2, while the modified cantilever results in a GC of 89 ± 5 J/m2. The role of the phase angle and stress state on GC and the resulting spread in the data is discussed. The advantages and limitations of the two geometries are contextualized for testing a variety of thermal spray coating/substrate combinations and other ceramic/metal interfaces.",

keywords = "interface fracture energy, modified cantilever, modified clamped beam, phase angle, thermal spray coatings",

author = "Saim Abbas and Sanjay Sampath and Sudhanshu Mallick and Jaya, \{B. Nagamani\}",

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T1 - Influence of Geometry on Interface Fracture Energy Measurements of Thermal Spray Coatings

AU - Abbas, Saim

AU - Sampath, Sanjay

AU - Mallick, Sudhanshu

AU - Jaya, B. Nagamani

PY - 2025/11

Y1 - 2025/11

N2 - Two novel bending-based interface fracture energy measurement techniques, the modified clamped beam and the modified cantilever, are compared on a model system consisting of air plasma–sprayed alumina over mild steel. Multiple values of interface energies are obtained on the same sample using digital image correlation (DIC)–based crack opening displacement (COD) measurements, converting both these techniques into high throughput. The mean and standard deviation in interface fracture energy (GC) are found to be geometry dependent, with the modified clamped beam yielding a GC of 56 ± 16 J/m2, while the modified cantilever results in a GC of 89 ± 5 J/m2. The role of the phase angle and stress state on GC and the resulting spread in the data is discussed. The advantages and limitations of the two geometries are contextualized for testing a variety of thermal spray coating/substrate combinations and other ceramic/metal interfaces.

AB - Two novel bending-based interface fracture energy measurement techniques, the modified clamped beam and the modified cantilever, are compared on a model system consisting of air plasma–sprayed alumina over mild steel. Multiple values of interface energies are obtained on the same sample using digital image correlation (DIC)–based crack opening displacement (COD) measurements, converting both these techniques into high throughput. The mean and standard deviation in interface fracture energy (GC) are found to be geometry dependent, with the modified clamped beam yielding a GC of 56 ± 16 J/m2, while the modified cantilever results in a GC of 89 ± 5 J/m2. The role of the phase angle and stress state on GC and the resulting spread in the data is discussed. The advantages and limitations of the two geometries are contextualized for testing a variety of thermal spray coating/substrate combinations and other ceramic/metal interfaces.

KW - interface fracture energy

KW - modified cantilever

KW - modified clamped beam

KW - phase angle

KW - thermal spray coatings

UR - https://www.scopus.com/pages/publications/105012584612

U2 - 10.1111/ffe.70054

DO - 10.1111/ffe.70054

M3 - Article

AN - SCOPUS:105012584612

SN - 8756-758X

VL - 48

SP - 4541

EP - 4551

JO - Fatigue and Fracture of Engineering Materials and Structures

JF - Fatigue and Fracture of Engineering Materials and Structures

IS - 11

ER -

Influence of Geometry on Interface Fracture Energy Measurements of Thermal Spray Coatings

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Keywords

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