Abstract
This paper aims to assess the effect of shape irregularity on contact damage in a brittle coating on a stiff metal substrate. Hertzian contact damage in a dental porcelain layer over a Ni-Cr alloy substrate in both curved and flat geometries was studied using finite element analysis and experimental investigation. Three failure modes were examined with varying porcelain layer thickness: cone cracking at the top surface of the porcelain, interface cracking at the layer/substrate interface and plastic deformation below the contact area in the substrate. It is shown that curvature has very little effect on the initiation of surface cone cracks in this system, but substantial effect on the initiation of interface radial cracks. In particular, curvature reduces the critical load for the onset of interface cracks
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