Scratch Damage Research Articles

Atomistic insights into scratch-induced structural evolution of silica glass

Understanding the mechanism of scratch damage is vital to developing better scratch-resistant glasses. To this extent, employing molecular dynamics simulations and experiments, we investigate the scratch damage of silica glass against a rigid diamond indenter. The glass surface is pre-indented to a constant depth and then dragged to simulate a linear scratch, and the structural impact in the indent-to-scratch transitioning phase is examined. We observe that despite the differences in length and timescales, the simulated values of indentation hardness and coefficient of friction exhibit excellent agreement with experimental values from nanoindentation and atomic force microscopy experiments. Interestingly, analysis of the subsurface deformation in the scratched region reveals densification and shear flow, in contrast to pure densification, as in the case of indentation. Furthermore, similar percentages of recovery from experiments and simulation reveal that the reversible component of plastic deformation owing to densification is comparable in both cases. Finally, in contrast to the common hypothesis, we demonstrate that while the bond angles and lengths recover significantly, the ring structure does not recover upon annealing, although they exhibit some relaxation. Thus, the present study sheds new light on the crucial role of the medium-range structure of glasses subjected to scratch deformation.

Fracture properties of carbon/glass fiber composite laminates with surface scratch damage

Carbon/glass fiber reinforced polymer composite panels may experience minor surface scratches during processing or use. These shallow scratches can expand and potentially lead to dangerous fracture failure as the specimens are continually loaded. This study presents a closed form non-LEFM model for predicting the fracture performance of materials with slight scratches. First, 3-p-b tests and direct tensile tests were conducted on 115 carbon/glass fiber composite laminated panel specimens. A comparison of the two test methods revealed that 3-p-b tests were more suitable for analyzing quasi-brittle fracture in carbon/glass fiber composites. The tensile strength ft and fracture toughness KIC of 3-p-b specimens with and without notched were discussed using the weighted average calculation method to determine the thickness of the “composite” single-layer prepreg as the characteristic composite unit Cch. A normal distribution method was also introduced to analyze the experimental discrete points, covering almost all the experimental scatterers with desired reliability. Furthermore, the same method was applied to specimens with different layup methods, and the data analysis confirmed its effectiveness. As the seam-thickness ratio α increases within a certain range, the tensile strength ft showed an overall increasing trend and the peak load Pmax showed a decreasing trend. Additionally, the laboratory routine dimensions can be utilized to efficiently predict the fracture of large size members with defects at the same thickness, which is significant for the safe design of composite structures.

Fabrication of chitosan-encapsulated microcapsules containing wood wax oil for antibacterial self-healing wood coatings

Wood multifunctional smart coating is a new functional coating that combines smart material technology with traditional wood. In this study, wood wax oil based on thistle oil and flaxseed oil was used as the core material, and chitosan was used as the wall material to prepare self-repairing antibacterial microcapsules. The optimal preparation conditions were found to be an oil-water ratio (OWR) of 2:1, a core-to-wall ratio of 3:1, using OP-10 as the emulsifier at a concentration of 10.0 %, and a crosslinker concentration of 0.18 g/mL. The encapsulation efficiency of microcapsules was 73.7 % by spray drying, and the thermal stability was improved. The chitosan microcapsules exhibit the characteristics of water sensitivity and acid selective response, with rapid release at pH 7.0. Blending microcapsules at concentrations of 2.0 %, 5.0 %, and 8.0 % with UV topcoat and applying them to walnut plywood resulted in a multifunctional wood coating. Artificially simulated daily scratch damage was effectively repaired within 7 d. Furthermore, the 10.0 % microcapsules demonstrated antibacterial properties against Escherichia coli (E. coli) and Escherichia coli (E. coli), with an antibacterial E. coli and S. aureus rate of up to 75.82 % and 42.96 %. The IC50 of the wood coatings against E. coli was 5.667, while against S. aureus it was 15.45. The minimum inhibitory concentration (MIC) of the microcapsules against both E. coli and S. aureus was 10.0 %. The coating film containing 2.0 % microcapsules demonstrated superior overall performance. This research established a foundation for the development of self-healing antibacterial coatings for wood and addressed the gap in dual-functional self-healing antibacterial paint films for wood.

Natural light‐triggered microcapsules for non‐contact and autonomous healing of surface damages on insulating materials

AbstractIn the process of curing or service, epoxy resin is prone to crack damage due to complex stress, resulting in material performance degradation and other catastrophic accidents. Self‐healing microcapsules offer an effective strategy to address the aforementioned issues and enhance the long‐term durability of materials. However, traditional microcapsules face challenges in achieving non‐contact repair, as the healing agent requires high temperature or other extreme conditions to achieve curing, which necessitates the artificial provision of these conditions. Moreover, such extreme conditions may accelerate equipment aging or negatively impact the matrix material. To address these issues, this paper reports a photosensitive microcapsule that can achieve healing by natural light for non‐contact self‐healing of insulating composites. In particular, SiO2 nanoparticles are incorporated into the shell of the microcapsules to construct a UV shielding layer, effectively preventing premature curing and failure of the untriggered microcapsules. Experimental results indicate that the proposed photosensitive microcapsule@SiO2 exhibits excellent thermal stability, remaining intact at temperatures up to 200°C. With a healing agent content of approximately 77.5%, the photosensitive microcapsule@SiO2 ensures effective repair. Furthermore, when cross‐linked with epoxy resin, it has minimal negative impact on the epoxy matrix, with a slight improvement in mechanical properties. The composites demonstrate outstanding self‐healing performance in response to mechanical scratch damage. Without the need for any artificial stimuli, the healing process can be easily activated by natural light, facilitating intelligent, contactless, and autonomous self‐healing.

Study on fretting friction properties based on GCr15 alloy and liquid epoxy resin protective coatings on GCr15 alloy

GCr15 alloy steel is a representative alloy steel of high carbon chromium bearing steel, with good comprehensive performance. However, the fretting wear and fatigue at the interface of the GCr15 friction pair greatly reduce its service life. In this study, the friction pair of GCr15 alloy was prepared by the surface treatment of epoxy resin coating. The tangential fretting wear experiments were conducted on the samples with the point contact mode in an SRV-IV multifunctional tester to investigate the evolution law of coefficient of fretting wear, dissipation energy and damage varying with the normal load and displacement amplitude. The results showed that the coefficients of the friction pairs treated with epoxy resin composite materials are lower than those of GCr15-GCr15 friction pairs under the same normal load and displacement amplitude, and the friction coefficients of both types of friction pairs gradually decreased with the increase of normal load and the decrease of displacement amplitude. At the same time, epoxy resin coating treatment reduced the dissipation energy of fretting wear. From the perspective of damage protection, GCr15-GCr15 exhibits severe scratch damage, micropores, and microcracks after friction experiments, while the epoxy resin coating mainly showed furrow. In addition, the decrease in hardness of polymer composite coating increased the wear rate of the samples to a certain extent.

Hierarchical Structure with Microcrater Covered with Nanograss Enhancing Condensation and Its Antifrosting/Anti-Icing Performance Inspired by Euphorbia helioscopia L.

Over an extended period of evolution and natural selection, a multitude of species developed a diverse array of biological interface features with specific functions. These biological structures provide a rich source of inspiration for the design of bionic structures on superhydrophobic surfaces. Understanding the functional mechanism of plant leaves is of paramount importance for the advancement of new engineering materials and the further promotion of engineering applications of bionic research. The hierarchical structure of microcrater-covered nanograss (MCNG) on the surface of E. helioscopia L. leaf provided the inspiration for the bionic MCNG surface, which was successfully prepared on a copper substrate by hybrid laser micromachining technology and chemical etching. The combined action of texture structure and surface chemistry resulted in a contact angle of 169° ± 1° for MCNG surface droplets and a rolling angle of less than 1°. Notably, the condensation-induced adhesion force does not augment with the increase of the temperature difference, which facilitated the shedding of hot droplets from the surface. The microscope observation revealed a high density of condensed droplets on the MCNG surface and the tangible jumping behavior of the droplets. The fabricated MCNG also demonstrated excellent antifrost/anti-icing abilities in low-temperature and high-humidity environments. Finally, the study confirmed the exceptional mechanical durability and reusability of the MCNG surface through various tests, including scratch damage, sandpaper wear, water flow impact and flushing, and condensation-drying cycle tests. The nanograss can be effectively protected within the microcrater structure. This research presents a promising approach for preventing and/or removing unwanted droplets in numerous engineering applications.

Influence of mechanical properties on material deformation behavior of different ceramics in scratching

To understand the differences in material removal behavior during grinding for different ceramics, scratching of Al2O3, AlN, Si3N4 and ZrO2 (3Y-TZP) ceramics by a cube-corner diamond indenter was investigated in this paper. Scratching characteristics, including material deformation, scratching force, coefficient of friction (COF) and scratching damage of different ceramics were compared and analyzed. Elastic recovery rate model and stress field model were built to analyze the mechanism of material deformation and scratching damage during scratching on different ceramics. The results demonstrated that material deformation behaviors vary significantly, and depend on mechanical properties of the ceramics. Ceramics with higher hardness exhibit shallower penetration depth of scratching, while higher fracture toughness results in shorter maximum surface damage distance. Elastic recovery rate model can predict the extent of material deformation. The ceramic with the highest elastic recovery rate is Al2O3, followed by Si3N4, ZrO2, and finally AlN. Elastic recovery rate decreases with increase in force. In stress field model, AlN exhibits the highest maximum principal stress, followed by Al2O3 and Si3N4, with ZrO2 displaying the lowest stress. These distribution patterns are consistent with the results of scratching damage pattern.

Superhydrophobic Surfaces with Excellent Ice Prevention and Drag Reduction Properties Inspired by Iridaceae Leaf.

The anti-icing and drag-reduction properties of diverse microstructured surfaces have undergone extensive study over the past decade. Nonetheless, tough environments enforce stringent demands on the composite characteristics of superhydrophobic surfaces (SHS). In this study, fresh composite structures were fabricated on a metal substrate by nanosecond laser machining technology, drawing inspiration from the hardy plant Iridaceae. The prepared sample surface mainly consists of a periodic microrhombus array and irregular nanosheets. To comprehensively investigate the effect of its special structure on surface properties, three surfaces with different sizes of rhombic structures were used for comparative analysis, and the results show that the SH-S2 sample is optimal. This can significantly delay the freezing time by an impressive 1404 s at -10 °C while revealing the sample surface anti-icing strategy. In addition, the rheological experiments determined over 300 μm of slip length for the SH-S2 sample, and the drag reduction rate of the surface reaches nearly 40%, which is well aligned with the results of the delayed icing experiments. Finally, the mechanical durability of the SH-S2 surface was investigated through scratch damage, sandpaper abrasion, reparability trials, and icing and melting cycle tests. This research presents a new approach and methodology for the application of SHS on polar ship surfaces.

Research on point-supported rotational semi-rigid energy-dissipation connection for precast-cladding-panel at connection level

A novel point-supported rotational semi-rigid energy-dissipation connection for precast cladding panels (PRSEC) is proposed in this paper. The PRSEC, utilizing combined mechanical mechanisms involving friction and bending parts, could transform from a rigid connection into a flexible energy-dissipative connection as the seismic action increased. Theoretical predictions of PRSEC are presented, followed by a coordinated design method with the precast cladding panels. Subsequently, monotonic and cyclic loading tests are conducted to investigate the semi-rigid characteristic of PRSEC. Two distinctive working stages, the static friction stage and the sliding friction stage, are clearly captured in the monotonic test results. Additionally, the cyclic tests reveal that the PRSEC specimens exhibit favorable hysteretic performance, characterized by a stable load capacity, favorable deformation ability, and efficient energy dissipation capacity. The NAO friction pads exhibit a fragmented damage pattern, while the brass friction pads demonstrate a linear scratch damage pattern. No cracks or tears are observed on the surface of the bending part, which demonstrated a track-like deformation mode. Both PRSEC specimens with NAO and brass friction pads show satisfactory low-cycle fatigue performance. Furthermore, finite element analyses are conducted using Abaqus to reveal the working mechanism of the friction and bending parts. The influence of the relative parameters is also summarized based on both experimental and numerical analyses. Subsequent research would be conducted to analyze the interaction between PRSEC and precast cladding panels at the structural level to provide a reference for the design of structures employing PRSEC.

Regression Model for the Mechanical Properties of PVC-P Geomembranes with Scratch Damage

Regression Model for the Mechanical Properties of PVC-P Geomembranes with Scratch Damage

Research on hysteretic performance of a semi-rigid energy dissipation connection for precast cladding panels

A novel semi-rigid energy dissipation connection (SEDC), capable of transitioning the precast cladding panel from a rigid connection to a flexible connection with the primary structure as the seismic action increases, is proposed in the present study. The combination of the bending part and friction part endows the connection with the ability to provide adjustable sliding force and sufficient energy dissipation for the precast cladding panel. The design methods of SEDC, including the elastic stiffness, the yield force, the yield displacement, and the bear capacity, are proposed, followed by a coordinated design method between the precast cladding panels and the primary structure based on SEDC. Fourteen SEDC specimens are designed and tested under monotonic and cyclic loading tests to investigate the semi-rigid workability of SEDC and to evaluate the influence of design parameters of the bending and friction parts. Two working processes, which are the static friction process and the sliding friction process, are clearly reflected by the monotonic test results. The cyclic test results indicate that the SEDC specimens demonstrate satisfactory plastic development with full hysteretic curves, stable load capacity, reliable deformation ability, and favorable energy dissipation ability. The U-shaped bending plates exhibited a track-like deformation pattern without any observed tears or cracks. The NAO friction pads demonstrated a fragmented damage pattern, while the Brass friction pads demonstrated a linear scratch damage pattern. SEDC specimens equipped with Brass friction pads exhibited better low-cycle fatigue performance, which can be attributed to the favorable wear resistance of the Brass material. In addition, finite models of SEDCs are established and validated based on Abaqus. The combined working mechanism of SEDC, including the contribution ratio of load capacity and dissipated energy from the bending part and the friction part, is clearly revealed. Furthermore, the influence of parameters including the thickness (t), width (B), straight section length (l), radius (R), and height (h) of the bending part, as well as the pre-tightening force (pc) and the friction coefficient (f) of the friction part, are also summarized based on both the experimental and numerical analyses. Further discussions, including the calculation of the seismic behavior factor and the measurements for accurate construction, are conducted.

Phyllostachys Viridis-Leaf-like MLMN Surfaces Constructed by Nanosecond Laser Hybridization for Superhydrophobic Antifogging and Anti-Icing.

In nature, many species commonly evolve specific functional surfaces to withstand harsh external environments. In particular, structured wettability of surfaces has attracted tremendous interest due to its great potential in antifogging and anti-icing properties. Phyllostachys Viridis is a resistant low-temperature (-18 °C) plant with superhydrophobicity and ice resistivity behaviors. In this work, with inspiration from the representative cold-tolerant plants leaves, a unique multilevel micronano (MLMN) surface was fabricated on copper substrate by ultrafast laser process, which exhibited superior superhydrophobic characteristics with the water contact angle > 165° and rolling angle< 2°. In the dynamic wettability experiment, the rebound efficiency of the droplet on the MLMN surface reached 20.6%, and the contact time was only 10.6 ms. In the condensation experiment, the nucleation, growth, merging, and bouncing of fog drops on the surface was distinctly observed, indicating that rational texture structures can improve the antifogging performance of the surface. In the anti-icing experiment, the freezing time was delayed to 921 s at -10 °C, and the freezing time of salt water reached a staggering 1214 s. Moreover, the mechanical durability of MLMN surfaces was confirmed by scratch damage, sandpaper abrasion, and icing and melting cycle tests, and their repairability was evaluated for product applications in practice. Finally, the underlying antifogging/anti-icing strategy of the MLMN surface was also revealed. We anticipate that the investigations offer a promising way to handily design and fabricate multiscale hierarchical structures with reliable antifogging and anti-icing performance, especially in saltwater-related applications.

Surface hardness and scratch characteristics of nanosecond laser colored Ti-based metallic glass

Pulsed laser irradiation is widely used for coloring metallic glass (MG) surfaces due to its efficient and clean processing characteristics. However, the hardness and tribological properties of laser colored MG surfaces have rarely been studied. In this study, various colors were prepared on Ti-based MGs by nanosecond pulsed laser irradiation, and the mechanical properties of the colored surfaces were subsequently investigated. Before hardness testing, the colored surfaces were slightly polished and characterized for surface morphology and phase composition. The hardness of the colored surfaces was measured by a nanoindentation instrument, and the corresponding load depth curves and residual indentations were obtained. The results showed a 39% increase in hardness compared to the as-cast surface. Scratch tests were performed to investigate the tribological properties of the colored surfaces. The residual scratches and three dimensional (3D) topographies exhibited diverse features, and the scratch damage mechanism was analyzed accordingly. This study broadened the knowledge of surface hardness and tribological properties, and illustrated the application potentials of laser colored MGs.

Modeling of material removal rate considering the chemical mechanical effects of lubricant, oxidant, and abrasive particles for aluminum chemical mechanical polishing at low pressure

Lubricants are widely used for aluminum (Al) chemical mechanical polishing (CMP) to eliminate surface scratch damage. Understanding of the fundamental of CMP material removal mechanisms including lubrication is crucial to offer insights into the control and optimization of the polishing process. This paper proposes a novel material removal rate (MRR) model based upon molecular-scaled removal mechanism, micro-contact force equilibrium theory, chemical reaction kinetics and diffusion effects, with further considering the lubricant effect on the removal rate at low polishing pressure. Moreover, the presented model also clarifies the nonlinear dependence of removal rate on lubricant concentration, oxidizer concentration, and abrasive concentration. The model prediction results could provide qualitative insights into the influence of lubricant concentration, oxidizer concentration, and abrasive concentration on MRR, thus providing theoretical foundation and support for delineating the Al-CMP process at low pressure. Finally, it is found that the theoretical predictions possess qualitative agreement with the experimental results.

Thermal and tribo-mechanical properties of high-performance poly(etheretherketone)/reduced graphene oxide nanocomposite coatings prepared by electrophoretic deposition

The thermal stability and degradation, near-to-surface mechanical properties, and scratch resistance and damage mechanism of poly(etheretherketone) (PEEK)/reduced graphene oxide (RGO) nanocomposite coatings are analyzed and discussed in terms of their nanosheet content and microstructure. Although RGO modified the thermal stability and degradation of the polymeric matrix, for instance, by slightly reducing the onset degradation temperature, its addition was not a limiting factor in the PEEK processing. Respecting the microstructural features induced by the nanosheets, the nanocomposite coatings were found to exhibit (i) a partially exfoliated and large-scale co-continuous morphology related to RGO nanosheets whose basal planes were mainly aligned with the coating surface, (ii) a dendritic morphology of PEEK domains related to transcrystallinity, (iii) and irregular domains associated with the deposition of PEEK particles wrapped by the nanosheets. The changes provoked by RGO in the morphology and PEEK crystalline phase influenced the near-to-surface mechanical properties, scratch resistance, and scratch damage mechanism of the nanocomposite coatings. Within this context, the interlayer strength between the nanosheets in the large-scale co-continuous morphology and PEEK transcrystallinity had an important effect. Furthermore, the random-bumpy surface texture formed by the irregular PEEK domains together with the conformal cracking damage mechanism was decisive in the scratch response of the PEEK/RGO nanocomposite coatings. The comprehensive characterization carried out in this work concludes that PEEK/RGO electrophoretic coatings are suitable for a variety of applications requiring tribo-mechanical resistance.Graphical

Scratch behaviors of polyacrylate-based hard coatings on alternating multi-layered PMMA+PC substrates

In our previous work [1], the scratch behaviors of alternating multi-layered polymethyl methacrylate (PMMA)/polycarbonate (PC) laminates were studied. Generally, a hard coating layer must be introduced to the surface of PMMA + PC laminate to further enhance its hardness and scratch resistance. In this work, the same laminates used in our previous work were coated by a UV-cured polyacrylate hard layer, and the scratch behaviors and relating mechanisms of hard coating (HC) systems were investigated via both progressive normal load scratch test and pencil hardness test. Sliding counterfaces of two tests were stainless steel ball with a diameter of 1 mm and cylinder made of pencil core with a diameter of 2 mm, respectively. Length, width and thickness of test specimen were 150 mm, 33 mm and 1.6 mm, respectively. The effects of HC's thickness and substrate's hardness on scratch behaviors of HC systems were also included. In both scratch tests, experimental results demonstrated that scratch damages of HC systems were featured with dense periodic cracks. Finite element modeling (FEM) revealed that the formation of such crack types was attributed to the maximum principal stress perpendicular to crack propagation direction. Furthermore, it was found that the scratch resistances of HC systems were enhanced as thickness of HC or hardness of substrate increased, the mechanism behind which were found to be decreasing of the maximum principal stress and consequent delaying of crack formation as revealed through FEM.

High-fidelity computational modeling of scratch damage in automotive coatings with machine learning-driven identification of fracture parameters

As one of the key components of a vehicle, automotive coating systems are typical micro-size multilayer composites, which normally suffer from intricate scratch damage. Currently, it is a challenging task to reproduce the complex physical phenomena of automotive coatings with micron thickness using numerical simulations. The purpose of this work is to develop a computational framework for an accurate evaluation of such scratch damage. To achieve this end, a high-fidelity finite element (FE) model is proposed, where a rate-dependent cohesive zone model is developed to account for coating crack behaviors. A reverse identification approach based on the machine learning (ML) method is suggested to determine the rate-dependent cohesive parameters that are difficult to be measured via direct experiments. In the course of recognition, this work develops a two-step regional data augmentation strategy based on the existing single-shot recognition method. The developed strategy is capable of reducing the number of training data samples, while improving identification accuracy and robustness. With the identified cohesive parameters, the proposed finite element model is applied to simulate speed-dependent coating scratch behaviors. The good agreement between numerical and experimental results demonstrates the capacity of our developed computational framework for coating scratch problems.

Nanoscratch Testing of 3Al2O3·2SiO2 EBCs: Assessment of Induced Damage and Estimation of Adhesion Strength

In this study, the structural integrity of mullite (3Al2O3·2SiO2) films, deposited on silicon carbide (SiC) substrates using chemical vapor deposition (CVD), was investigated via increasing load nanoscratch tests. The films were configured by mullite columns of stoichiometric composition growing from a silica-rich layer in contact with the SiC substrate. Controlled damage was induced in the 3Al2O3·2SiO2 films at relatively low scratch loads. Radial and lateral cracking were applied until final delamination and repeated chipping were achieved as the load increased. The intrinsic integrity of the 3Al2O3∙2SiO2 film and the performance of the coated 3Al2O3·2SiO2/SiC system, regarded as a structural unit, were analyzed. With the aid of advanced characterization techniques at the surface and subsurface levels, the configuration and morphology of the damage induced in the coated system by the nanoscratch tests were characterized, and the scratch damage micromechanisms were identified. Finally, the adhesion of the film, in terms of energy of adhesion and interfacial fracture toughness, was determined using different models proposed in the literature. The results from this investigation contribute to the understanding of the mechanical performance and structural integrity of EBC/SiC-based systems, which over the past few years have increasingly been implemented in novel applications for gas turbines and aircraft engines.

Effects of Interlaminar Failure on the Scratch Damage of Automotive Coatings: Cohesive Zone Modeling.

Interlaminar failure caused by scratches is a common damage mode in automotive coatings and is considered the potential trigger for irreversible destruction, i.e., plowing. This work strives to numerically investigate the mechanisms responsible for the complex scratch behavior of an automotive coating system, considering the interfacial failure. A finite element model is developed by incorporating a large deformation cohesive zone model for scratch-induced debonding simulation, where the mass scaling technique is utilized to minimize computational burden while ensuring accuracy. The delamination phenomenon of the automotive coating is reproduced, and its effects on scratch damage behavior are analyzed. Accordingly, it is revealed that the interlaminar delamination would produce significant stress redistribution, which leads to brittle and ductile damage of the coating and consequently affects the formation of plowing. Eventually, parametric studies on the effects of interfacial properties are performed. They demonstrate that the shear strength and shear fracture energy dominate scratch-induced delamination.

The scratch characteristics of laser nitrided Zr-based metallic glass surface

Improving the surface hardness and tribological characteristics of metallic glasses (MGs) is meaningful for their applications as surface contact materials. In this study, nanosecond laser nitriding was performed on Zr-based MG to improve its surface properties. Three types of laser nitrided surfaces with different hardness were prepared, and their tribological characteristics were systematically investigated by means of the scratch test. The experimental results indicated that compared with the as-cast MG, the hardness of these three laser nitrided surfaces was increased by 47.94%, 114.56%, and 171.99%, and their coefficients of friction were reduced by 29.12%, 65.05%, and 71.84%, respectively. Furthermore, the residual scratches and surrounding chips exhibited various features under different conditions, and the scratch damage mechanisms were analyzed accordingly.