The multidisciplinary approach has been adopted to model the formation and propagation of blistering effect for evaluation of useful coating life in the multi-layered coating–substrate system. A prognostic model of de-bonding driving force has been formulated as a function of material science, solid mechanics and fracture mechanics properties to estimate critical, safe and fail conditions of the coating–substrate system. The blister growth velocity rate is also included in the developed model to estimate the blister propagation as a function of diffusion-induced stress and residual stress. The proposed prognostic modelling for the formation and propagation of blistering effect are combined to form an assessment model for the evaluation of useful coating life of the multi-layered coating–substrate system and validated through experimental observation.
ZhangN-H, XingJ-J.An alternative model for elastic bending deformation of multilayered beams. J Appl Phys. 2006;100:103519.
5.
HuY, HuangW.Elastic and elastic-plastic analysis of multilayer thin films: closed-form solutions. J Appl Phys. 2004;96:4154–4160.
6.
LiuH, MurarkaS.Elastic and viscoelastic analysis of stress in thin films. J Appl Phys. 1992;72:3458–3463.
7.
MalzbenderJ.Mechanical and thermal stresses in multilayered materials. J Appl Phys. 2004;95:1780–1782.
8.
MoodyN, VenkataramanS, NelsonJ, Interface roughness effects on adhesion of Ta 2 N films. MRS proceedings;1993; Cambridge University Press, 337.
9.
SarikayaO.Effect of some parameters on microstructure and hardness of alumina coatings prepared by the air plasma spraying process. Surf Coat Technol. 2005;190:388–393.
10.
YagmurL.Effect of microstructure on internal friction and Young's modulus of aged Cu–Be alloy. Mater Sci Eng A. 2009;523:65–69.
11.
FauchaisP, VardelleA.Thermal sprayed coatings used against corrosion and corrosive wear. 2012, INTECH Open Access Publisher.
12.
ChirimaGT, ZiedKM, RaviralaN, Numerical and analytical modelling of multi-layer adhesive-film interface systems. Phys Status Solidi B Basic Solid State Phys. 2009;246:2072–2082.
13.
NordinM, HerranenM, HogmarkS.Influence of lamellae thickness on the corrosion behaviour of multilayered PVD TiN/CrN coatings. Thin Solid Films. 1999;348:202–209.
14.
PommersheimJM, NguyenT, HartzfeldK.Prediction of blistering in coating systems. Washington, DC: ACS symposium series; 1998.
15.
BressersJ, PetevesS, SteenM.Coatings for hot section gas turbine components. Eur Struct Integr Soc. 2000;26:115–134.
16.
GalindoRE, Van VeenA, EvansJ, A modified blister test to study the adhesion of thin coatings based on local helium ion implantation. Thin Solid Films. 2005;471:170–176.
PrawotoY, DillonB.Failure analysis and life assessment of coating: the use of mixed mode stress intensity factors in coating and other surface engineering life assessment. J Fail Anal Prev. 2012;12:190–197.
19.
PrawotoY.Unified model for blister growth in coating degradation using weight function and diffusion concepts. Mater Corros. 2013;64:794–800.
20.
NazirM, KhanZA, SaeedA, A model for cathodic blister growth in coating degradation using mesomechanics approach. Mater Corros. 2016;67:495–503.
21.
NazirM, KhanZA, StokesK.A holistic mathematical modelling and simulation for cathodic delamination mechanism – a novel and an efficient approach. J Adhes Sci Technol. 2015;29:2475–2513.
22.
NazirM, KhanZA, SaeedA, A predictive model for life assessment of automotive exhaust mufflers subject to internal corrosion failure due to exhaust gas condensation. Eng Fail Anal. 2016;63:43–60.
23.
NazirM, KhanZA, SaeedA, Modeling the effect of residual and diffusion-induced stresses on corrosion at the interface of coating and substrate. Corrosion. 2015;72:500–517.
24.
NazirM, KhanZA, StokesK.Analysing the coupled effects of compressive and diffusion induced stresses on the nucleation and propagation of circular coating blisters in the presence of micro-cracks. Eng Fail Anal. 2016;70:1–15.
25.
SaeedA, KhanZ, MontgomeryE.Corrosion damage analysis and material characterization of Sherman and Centaur – the historic military tanks. Mater Perform Charact. 2013;2:20120016.
26.
SaeedA, KhanZA, HadfieldM, Material characterization and real-time wear evaluation of pistons and cylinder liners of the tiger 131 military tank. Tribol Trans. 2013;56:637–644.
27.
NazirMH, KhanZA, SaeedA, A model for cathodic blister growth in coating degradation using mesomechanics approach. Mater Corros. 2016;67:495–503.
28.
NazirMH, KhanZA, SaeedA, Modeling the effect of residual and diffusion-induced stresses on corrosion at the interface of coating and substrate. Corrosion. 2015;72:500–517.
29.
SaeedA, KhanZ, ClarkM, Non-destructive material characterisation and material loss evaluation in large historic military vehicles. Insight Non-Destr Test Cond Monit. 2011;53:382–386.
30.
SaeedA.Sustainable methodology of conserving historic military vehicles. Bournemouth, UK: Bournemouth University; 2013.
31.
SaeedA, KhanZA, NazirMH.Time dependent surface corrosion analysis and modelling of automotive steel under a simplistic model of variations in environmental parameters. Mater Chem Phys. 2016;178:65–73.
32.
NazirMH, KhanZA, StokesK.A holistic mathematical modelling and simulation for cathodic delamination mechanism – a novel and an efficient approach. J Adhes Sci Technol. 2015;29:2475–2513.
33.
KhanZA, GroverM, NazirMH.The implications of wet and dry turning on the surface quality of EN8 steel. Trans Eng Technol. 2015;413–423. Springer.
NazirM, KhanZ, SaeedA, Modelling the effect of residual and diffusion induced stresses on corrosion at the interface of coating and substrate. Corrosion. 2016;72:500–517.
36.
NazirMH, KhanZA, StokesK.Optimisation of interface roughness and coating thickness to maximise coating-substrate adhesion – a failure prediction and reliability assessment modelling. J Adhes Sci Technol. 2015;29:1415–1445.
37.
NazirM, KhanZA, StokesK.A unified mathematical modelling and simulation for cathodic blistering mechanism incorporating diffusion and fracture mechanics concepts. J Adhes Sci Technol. 2015;29:1200–1228.
38.
NazirMH, SaeedA, KhanZ.A comprehensive predictive corrosion model incorporating varying environmental gas pollutants applied to wider steel applications. Mater Chem Phys. 2017;193:19–34.
39.
SaeedA, KhanZA, NazirH, Research impact of conserving large military vehicles through a sustainable methodology. Int J Herit Arch. 2017;1:267–274.
40.
NazirM, KhanZ.A review of theoretical analysis techniques for cracking and corrosive degradation of film-substrate systems. Eng Fail Anal. 2017;72:80–113.
41.
BajwaR, KhanZ, NazirH, Wear and friction properties of electrodeposited Ni-based coatings subject to nano-enhanced lubricant and composite coating. Acta Metall Sin (English Letters). 2016;29:902–910.
42.
KhanZA, PashaeiP, BajwaR, Fabrication and characterization of electrodeposited and magnetron-sputtered thin films. Int J Comput Methods Exp Meas. 2015;3:165–174.
43.
NazirMH, KhanZ.Maximising the interfacial toughness of thin coatings and substrate through optimisation of defined parameters. Int J Comput Methods Exp Meas. 2015;3:316–328.
44.
BajwaRS, KhanZ, BakolasV, Effect of bath ionic strength on adhesion and tribological properties of pure nickel and Ni-based nanocomposite coatings. J Adhes Sci Technol. 2016;30:653–665.
45.
BajwaRS, KhanZ, BakolasV, Water-lubricated Ni-based composite (Ni–Al2O3, Ni–SiC and Ni–ZrO2) thin film coatings for industrial applications. Acta Metall Sin (English Letters). 2016;29:8–16.
ArmelinE, OcampoC, LiesaF, Study of epoxy and alkyd coatings modified with emeraldine base form of polyaniline. Progr Org Coat. 2007;58:316–322.
48.
HsuehC-H.Modeling of elastic deformation of multilayers due to residual stresses and external bending. J Appl Phys. 2002;91:9652–9656.
49.
ZhangX, ShyyW, SastryAM.Numerical simulation of intercalation-induced stress in Li-ion battery electrode particles. J Electrochem Soc. 2007;154:A910–A916.
50.
MejlbroL.1996Cementa AB, Lund, Sweden.
51.
LiJC-M.Physical chemistry of some microstructural phenomena. Metall Trans A. 1978;9:1353–1380.
52.
FaulhaberS, MercerC, MoonM-W, Buckling delamination in compressed multilayers on curved substrates with accompanying ridge cracks. J Mech Phys Solids. 2006;54:1004–1028.
53.
HutchinsonJ, ThoulessM, LinigerE.Growth and configurational stability of circular, buckling-driven film delaminations. Acta Metall Mater. 1992;40:295–308.
ChuangT, NguyenT.1997Proceedings of the First International Conference DFI-1, Vienna, Austria, CRC Press.
56.
MartinJ, EmbreeE, TsaoW.Non-osmotic, defect-controlled cathodic disbondment of a coating from a steel substrate. J Coat Technol. 1990;62:25–33.
57.
StratmannM, LengA, FürbethW, The scanning Kelvin probe; a new technique for the in situ analysis of the delamination of organic coatings. Prog Org Coat. 1996;27:261–267.
58.
WanK-t, LiaoK.Measuring mechanical properties of thin flexible films by a shaft-loaded blister test. Thin Solid Films. 1999;352:167–172.
59.
JensenH.Delamination of coatingsHandbook of materials behavior models. Lyngby, Denmark: Academic press; 2001. p. 582–586
60.
KappesM, FrankelG, SridharN.Adhesion and adhesion degradation of a pressure sensitive tape on carbon steel. Prog Org Coat. 2010;69:57–62.
61.
StratmannM, FeserR, LengA.Corrosion protection by organic films. Electrochim. Acta. 1994;39:1207–1214.
62.
AllaharKN, OrazemME, OgleK.Mathematical model for cathodic delamination using a porosity–pH relationship. Corros Sci. 2007;49:3638–3658.
