Adhesion along metal–polymer interfaces during plastic deformation

In this paper a numerical study is presented that concentrates on the influence of the interface roughness that develops during plastic deformation of a metal, on the work of adhesion and on the change of interface energy upon contact with a glassy polymer. The polymer coating is described with a constitutive law that mimics the behavior of Poly-Ethylene Terephthalate. It includes an elastic part, a yield stress, softening and hardening with increasing strains. For the interface between the metal and the polymer a mixed-mode (mode I and II) stress-separation law is applied that defines the interface energy and an interaction length scale. At the onset of deformation the surface of the substrate has a self-affine roughness characterized by the so-called Hurst exponent, a correlation length and an rms roughness amplitude, that evolves as a function of increasing strain. The findings are the following: the interface energy decreases until the strain at yield of the polymer coating. Interestingly, after yielding as the polymer starts to soften macroscopically, the decreasing average stress levels result in partial recovery of the interface energy at the interface. At higher strains, when macroscopic hardening develops the recovery of the interface stops and the interface energy decreases. The effect of coating thickness is discussed as well as the physical relevance of various model parameters.