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Thin Solid Films 520 (2012) 2375–2389

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Thin Solid Films


journal homepage: www.elsevier.com/locate/tsf

Critical review

Toughness evaluation of hard coatings and thin films


Sam Zhang ⁎, Xiaomin Zhang
School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore

a r t i c l e i n f o a b s t r a c t

Available online 24 September 2011 Enormous progress has been achieved over the past decade in evaluating the toughness of hard coatings and
thin films. This paper reviews methodologies developed based on indentation, bending, and microtensile
Keywords: testing. In addition, we discuss a recent development in fracture toughness measurement which involves
Thin films the application of macrotension to a substrate in order to induce microtension in a patterned thin film.
Coatings © 2011 Elsevier B.V. All rights reserved.
Fracture toughness

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2375
2. Qualitative assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2376
2.1. Indentation plasticity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2376
2.2. Scratch toughness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2376
3. Quantitative toughness characterization for coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2377
3.1. Toughness evaluation from radial cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2377
3.2. Toughness evaluation from circumferential cracking and spallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2379
3.3. Toughness evaluation from channel cracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2382
4. Microtensile testing of fracture toughness for standalone thin films . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2384
4.1. Inchworm actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2385
4.2. Membrane deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2385
4.3. Tension by residual stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2386
4.4. Bulging of films . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2387
4.5. Macrotension of substrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2387
5. Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2388
5.1. Hard coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2388
5.2. Thin films . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2388
Acknowledgments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2388
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2388

1. Introduction withstand without fracture [3]. It is measured as the maximum stress


intensity factor under plane strain condition [4–5]. To meet the “plane
Toughness is one of the important mechanical properties of a ma- strain” condition, the specimen dimensions, t, a and (W−a), should
terial. The term toughness refers to the ability of a material to absorb respectively satisfy the following inequality:
energy during deformation up to fracture [1–2], usually measured in
terms of fracture toughness. In classical mechanics, fracture toughness !2
KIC
refers to the stress resistance of a material to fracture in the presence t; a; ðW−aÞ ≥ 2:5 ; ð1Þ
σy
of a flaw, i.e. the highest stress intensity that the material can

where t and W are specimen thickness and width respectively, a is the


flaw size, σy is the yield stress, and KIC is the critical stress intensity
⁎ Corresponding author. Tel.: + 65 6790 4400; fax: + 65 6791 1859. that a material can withstand without fracture. In essence, Eq. (1) re-
E-mail address: msyzhang@ntu.edu.sg (S. Zhang). quires that the sample thickness should be large enough, while the

0040-6090/$ – see front matter © 2011 Elsevier B.V. All rights reserved.
doi:10.1016/j.tsf.2011.09.036
2376 S. Zhang, X. Zhang / Thin Solid Films 520 (2012) 2375–2389

initial crack length and the “no-crack” region (i.e., W− a) should not
be too small. For brittle bulk materials, the minimum thickness t is Plastic Elastic
several to tens of micrometers [5–6]. For thin films, however, where deformation deformation
t usually ranges from nanometers to a few micrometers, the plane
strain condition is not met.
Measurement of fracture toughness for bulk materials is classical,
and is done routinely in research or production using, for example,
the Charpy test, four-point or three-point bending, etc. [7–8]. Howev-
er, these methods barely apply for a thin film due to the size limitation
of the film thickness. Various methodologies have been developed for
microtensile testing of freestanding thin films, attempting to resolve
the technique difficulties in fabricating a standalone thin film speci-
men and then clamping and testing. For hard coatings bonded to sub-
strates, researchers make use of nanoindentation on coatings or
bending of ductile substrates to generate different types of coating
cracking, based on which various methods for fracture toughness
measurement are proposed. In fracture mechanics, coating cracking Fig. 1. Schematic plot of a nanoindentation load–displacement curve. Plasticity is calcu-
is a lot more complex. Some hypotheses were put forth for approxima- lated as OA/OB = plastic work / (plastic work + elastic work) [15–16].
tion in these methods, resulting in data treatment which is not compa-
rable. It is the aim of this paper to provide an overview of the available
toughness testing methodologies for hard coatings and thin films. Re- plasticity in terms of the mechanical work done during different
cent developments in microtensile testing of thin films will be stages of indentation measurement,
emphasized, especially the application of macrotension to a substrate
in order to induce microtension in a patterned thin film. Commonly MDP ¼ plastic work=ðplastic work þ elastic workÞ: ð3Þ
used qualitative methods will be described first.
In this paper, the term “film” refers to a freestanding film (i.e., However, plasticity is not toughness. Plasticity is the capacity to
without substrate), while “coating” refers to a film attached to a sub- resist plastic deformation (dislocation movement), while toughness
strate. It is necessary to make this distinction because a substrate ren- measures the ability of a material to resist crack propagation.
ders support and also brings constraints on the deformation and
fracture of the coating. 2.2. Scratch toughness
In all equations in this paper, K is the stress intensity factor of a
crack in a coating or a film and KC is the fracture toughness (critical Scratch testing is most widely used in evaluating the adhesion
stress intensity factor); for the opening mode of cracking, the sub- strength of hard coatings. During the test, a diamond stylus subjected
script ‘I’ is used; σ is the stress in a coating or a film; and t denotes to a linearly increasing load is drawn across the coated surface until ad-
film thickness. E, H, υ, n are the Young's modulus, hardness, Poisson's hesion failure is induced at a critical load. Generally (but not necessari-
ratio, and the hardening exponent of a coating or a film; in some ly), for hard coatings, microcracks appear in the scratch track before
cases, subscripts ‘f’ and ‘s’ are added to these symbols to distinguish failure occurs [19]. The minimum load at which the first crack occurs
coating and substrate. The terms a, b, c, W, l, etc. are used to describe is termed the “lower critical load” Lc1, and the load corresponding to
geometric sizes of testing specimens, and their meanings are defined complete delamination peeling of the coating is the “higher critical
in the text. load” Lc2 (Fig. 2). Some researchers have directly used the lower critical
load to indicate crack resistance, or even termed it “scratch toughness”
2. Qualitative assessment [9,12,14,20–23]. Zhang et al. [24] pointed out that the coating toughness
should be proportional to both the lower critical load and the difference
Indentation plasticity [9–11] and scratch toughness or “load-bearing between the higher and the lower critical load. Obviously, a coating can
capacity” [11–14] are, due to their operational simplicity [15], the two have an early crack, but if it fractures or peels off at very high load, it
most widely used qualitative methods for determining the toughness means that the coating has a very high “toughness” because, during
of coatings. the measurement, the coating has successfully resisted the propagation
of the crack. How long the coating can resist delamination and with-
2.1. Indentation plasticity stand further loading before catastrophic fracture occurs is as important

Indentation plasticity is defined as the ratio of the plastic displace-


ment divided by the total displacement in the load–displacement
curve of a nanoindentation measurement [16] (see, for example,
Fig. 1),

εp OA Total peeling
plasticity ¼ ¼ ; ð2Þ
ε OB
Cracking occurs
where εp is the plastic deformation and ε is the total deformation. OA
and OB are displacements defined in Fig. 1. Nanoindentation has
found a wide application in evaluating coating “toughness”. As reported,
nc-TiC/a-C coatings (nc = nanocrystalline and a = amorphous) have an
indentation plasticity of 40% [17], while that of nc-TiC/a-C(Al) coatings
is 55% [10].
In a related approach, Fox-Rabinovich et al. [11,18] proposed the Fig. 2. Typical scratch adhesion profile for nc-TiN/a-SiNx coatings deposited on silicon
“microhardness dissipation parameter” (see Fig. 1) to express the wafers [15].
S. Zhang, X. Zhang / Thin Solid Films 520 (2012) 2375–2389 2377

P calculation of the tensile stress induced in the coating during scratch


operation (see example in Fig. 4),
pffiffiffi
F KI ¼ σ bf ða; bÞ ð6Þ

σ is the tensile stress which induces the crack, a is the crack length,
and b is the crack spacing. f(a, b) is a nondimensional function depen-
dent on crack length a, and crack spacing b. Practical application of
2R 2a this method is difficult as there is no general expression for σ
obtained through a three-dimensional finite element model.

3. Quantitative toughness characterization for coatings

Groove track For a hard coating well bonded with the substrate, three types of
cracking patterns may be introduced through indentation of the coating
Fig. 3. Schematic diagram of a microscratch fracture toughness measurement with a
pressure P opening a crack of maximum width 2a out of a groove width 2R [25]. or bending of the substrate: radial cracking, circumferential cracking
and spallation, and channel cracking. All these modes of cracking are
used for quantitative analyses of the fracture toughness of the coating.
as crack initiation. A new parameter termed “scratch crack propagation
resistance” is thus proposed to directly use the scratch results to indi- 3.1. Toughness evaluation from radial cracks
cate coating toughness,
Radial cracks may be introduced at the surface of a ceramic mate-
CPRS ¼ Lc1 ðLc1 −Lc2 Þ: ð4Þ rial when indenting with a sharp edge indenter, e.g. a Vickers or a
Berkovich indenter (Fig. 5a). The radial cracking indentation method
Hoehn et al. [25] proposed a simplified model of a scratch in order was initially proposed for bulk materials [27]. The relationship be-
to formulate an expression for fracture toughness of coatings (see tween the fracture toughness and the length of radial cracks was
Fig. 3): established decades ago [28–29]:
 1=2  
2pfg  a 1=2 −1 R E P
KIC ¼ sin ; ð5Þ Kc ¼ α ; ð7Þ
R cotθ π
2 a H c3=2

where p is the pressure required to open the crack, R is the radius of in which P is the peak load at indentation; c is the crack length; and α
the indenter cone into the groove, 2a is the total crack length, and fg is the empirical constant which depends on the geometry of the in-
is the coefficient of grooving friction, which depends on the cone denter, α = 0.016 for both a Berkovich and Vickers type indenter.
angle 2θ and can be obtained from the scratch track width and the Elastic/plastic indentation fracture mechanics requires a median and
depth of penetration. However, the model is oversimplified, and the radial crack pattern being well developed (see Fig. 6 for definition
actual state of forces in the groove ahead and right below the tip is of median and radial). To ensure the complete formation of a “half-
much more complex and has to be taken into account for a better penny” cracking pattern, geometrically, it is required that c ≥ 2a (a
description of the process. Holmberg et al. [26] designed a 3-D finite is the radius of the impression (Fig. 6c)). The derivation of Eq. (7) as-
element model for the determination of fracture toughness via sumed “unlimited” sample thickness. In practice, the application of

Fig. 4. Schematic illustration of a stylus drawn along a coated sample. The material loading and response can be divided into three phases: ploughing, interface sliding, and pulling a
freestanding coating [26].
2378 S. Zhang, X. Zhang / Thin Solid Films 520 (2012) 2375–2389

a
Radial

b
Median

c
Half penny

Fig. 5. (a) Schematic illustration of radial cracking upon Vickers indentation, and
(b) ultra-low load nanoindentation radial cracks [27].

Eq. (7) requires that the depth d of the half-penny crack beneath the
surface be less than one-tenth of the thickness of the sample [30].
An ultralow load is applied during nanoindentation of coatings
[27] (Fig. 5b). For a coating with residual stress σr, the following rela-
tionship is commonly used [31–32] Fig. 6. Crack patterns in a brittle material upon Vickers indentation: (a) a radial crack;
(b) a median crack; (c) half-penny cracking (a combination of a radial crack and a me-
 1=2  
E P 1=2 dian crack) [41].
KIC ¼ α 3=2
þ Zσr c ; ð8Þ
H c

where Z is the crack shape factor given by [32] the load threshold by at least an order of magnitude compared with
that with a Vickers indenter [27]. Yet even here, the indentation
pffiffiffi d=c depth is still a few hundred nanometers for many brittle materials
Z ¼ 1:12 π 3π π  : ð9Þ
8 þ 8 ðd=cÞ
2
in order to induce a radial crack [34]. Therefore, for coatings, to intro-
duce well-developed radial cracks, the depth limitation of nanoinden-
Z = 1.26 for an idealized half-penny, i.e. the depth d of the crack is tation to exclude substrate effects is usually very difficult to meet.
equal to the crack length c, making the half-penny an ideal semicircle. Unlike standardized tests with a single well-defined crack in a
To meet the geometrical requirements of Eqs. (7) or (8), the in- well-defined loading configuration (like uniaxial tensile testing)
dentation depth (smaller than the depth d of the crack induced) [35], indentation induces a complex crack network and residual dam-
should be much less than 10% of the coating thickness. However, a age around the impression. This makes mechanical analysis extreme-
load threshold exists for the occurrence of the radial crack during in- ly difficult [29,36]. The “expanding cavity” model was adopted to
dentation. For most ceramic materials, the threshold load of a Vickers depict the damage zone of an indentation [28,37], but its reliability
or Berkovich indentation is 250 mN or more, and the corresponding is questionable [38–39]: experiments on bulk ceramic materials
impression produced is several micrometers in depth [27,33]. A revealed that the details of indentation cracking are extremely mate-
sharper angle indenter greatly reduces the threshold load for radial rial dependent. That is, the crack patterns are often not the idealized
cracks. For example, indenting with a cube-corner indenter reduces half-penny shape as assumed in the model [40–41]. In bulk ceramic
S. Zhang, X. Zhang / Thin Solid Films 520 (2012) 2375–2389 2379

materials, the actual crack pattern is obtained through observing the 3.2. Toughness evaluation from circumferential cracking and spallation
cross-section of the median/radial crack (Fig. 6c) [41–42], but it is al-
most impossible to do the same on coatings. Therefore, it is very dif- Circumferential cracking and spallation describe peeling of the
ficult to judge the reliability of Eqs. (7) and (8) for coatings. coating around the indentation (Fig. 8a). For a very brittle coating, it
A substrate indentation method was proposed to tackle the problem is generated upon nanoindentation. At spallation, a plateau forms in
of substrate influence [43]: indentation is conducted on the uncoated the load–displacement curve (see Fig. 8b) [34,44–47], which can be
side of the substrate surface such that the radial crack in the substrate used to produce a quantitative estimate of the coating fracture tough-
propagates into the coating. In this way, a single through-thickness ness. Li et al. (Fig. 8a) [34] suggested that fracture proceeds as follows:
crack is induced in the coating (Fig. 7a). The tougher the coating, the (1) the first circumferential through-thickness crack forms around the
shorter the crack in the coating (Fig. 7b). Based on the energy balance indenter by high stress in the contact area; (2) delamination and
principle, the following equation is obtained buckling occur around the contact area at the coating/substrate inter-
face due to high lateral pressure; (3) a second circumferential
through-thickness crack forms, and spallation is generated by high
Af Gf þ As Gs ¼ Asf As þ Ass Gs : ð10Þ

a
Gf and Gs are the strain energy release rates for coating and substrate, Af
and As are true cracked film and substrate areas. Asf, and Ass are cracked
areas when coating properties are identical to those of the substrate.
Through comparing the crack lengths of coated and uncoated sides, an
expression is obtained for the toughness of the coating
First ring-like
8 2 3 2 3 91=2 through-thickness
vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
ffi 2 vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
ffi 2 >
>
< uE  2 p ffiffiuE  2 = crack formation
26 ðϕb−aÞ u f 1−υ s 7 u f 1−υ
Kf ¼ Ks 41 þ λ t  5 þ 642ψc σr t t 
s 7
5 ;
>
: t E s 1−υ 2 E s 1−υ 2 >
;
f f

ð11Þ

where the subscript f′ refers to the film and s′ to the substrate; Ks is the
fracture toughness of the substrate; a and b are crack lengths as shown
in Fig. 7a; the dimensionless factors λ and ψc are 0.45 and 0.95 respec-
Delamination
tively, obtained from finite element model (FEM) calculations; and ϕ
and buckling
is a geometry term obtained from FEM.

Partial spalling
formation

Second ring-like
through-thickness Lateral cracking
crack formation during unloading

b
= 10 6 No coating
Indenter
-100 -80 -60 -40 -20 0 20 40 60 80 100
-10
Crack growth
-20
-30
-40
-50
Wedge model -60
Half-infinite plate model -70
-80
Fig. 8. (a) Schematic illustration of the three stages in nanoindentation fracture for thin
Fig. 7. (a) Schematic of indentation geometry; (b) crack growth front for different film coatings; (b) schematic of a load–displacement curve, showing a step during the load-
fracture toughnesses Kc [43]. ing cycle and associated energy release [34].
2380 S. Zhang, X. Zhang / Thin Solid Films 520 (2012) 2375–2389

bending stresses at the edges of the buckled thin coating. The third
stage, circumferential through-thickness cracking and spallation of
the coating, causes a sudden excursion of the indenter in displace-
ment, which induces a step in the load–displacement curve (Fig. 8b).
Given area ABC in Fig. 8b representing the energy U dissipated upon
coating cracking, the fracture toughness is obtained as
" #1=2
EU
KC ¼   ; ð12Þ
1−ν2 A

in which A = 2πCRt is the crack area, 2πCR is the crack length in the
coating plane, CR is the radius of circumferential through-thickness
crack formed around the indenter, and t is the coating thickness. E
and ν are Young's modulus and Poisson's ratio of the coating, respec-
tively.In Eq. (12), the coating fracture energy U is the irreversible
work Wirr of the indenter during the excursion from A to B.
Fig. 10. Schematic diagram representing the fracture energy U of a coating at the pla-
However, extraction of the irreversible work Wirr became the focal teau in a nanoindentation load–displacement curve: the segment (GB) represents a
point of much debate. denToonder et al. [44] suggested the lower and partial loading curve of the Si substrate; the dotted area (ABEF) represents the total
upper boundaries of the Wirr as shown in Fig. 9: the areas of OAB and work under the step (done by the indenter); the gray area 1 (ABH) represents the en-
ABFR, which correspond to the cases of full elastic deformation and full ergy released on circumferential cracking and spallation, while the area 2 (BEF) repre-
sents the energy of Si deformation [46].
plastic deformation of the coated system, respectively. Chen and Bull
[47] considered the area ABQE as representing the irreversible work
Wirr, with AE and BQ being the unloading curves at excursion start spallation of the coating, and segment GB represents a partial loading
point and end point. Further, they provided a method to obtain the curve of the silicon substrate.
unloading curve AE through the linear relationship between the ratio Malzbender et al. [44,49] studied the change of the irreversible en-
of displacement δf/δ1 and that of hardness over Young's modulus (Hs/Es): ergy Wirr versus load P through conducting a set of loading–unloading
cycles before and after the spallation of a coating. They found that the
δf H curve of Wirr vs. P was divided into several segments of straight lines
¼ 1−λ s ; ð13Þ
δ1 Es representing different events during cracking: radial cracking, delam-
ination, circumferential through-thickness cracking, and chipping
where Hs and Es are the hardness and Young's modulus of the substrate. (Fig. 11a). Apparently, the irreversible work Wirr was obtained from
λ =4.5 for a Berkovich indenter. δf, and δ1 are the residual displacement the energy difference Ufrc just before and after the circumferential
and full displacement of indentation as shown in Fig. 9. Expression (13) through-thickness cracking. Further, they found that Wirr is coating-
is developed for bulk materials without fracture [48]. It approximately thickness dependent [50]: the thinner the coating is, the larger the ir-
applies to coated systems in which the substrate dominates the deforma- reversible energy dissipation Wirr. The authors claimed that it is due
tion in deep indentations. In this way, the lower boundary ABE and the to the fact that more substrate deformation is involved for a thinner
upper boundary ABFE of the irreversible work Wirr are obtained. coating during indentation. Accordingly, the fracture energy U is
Michel et al. [46] realized that apart from the fracture energy U of obtained through extrapolating Wirr of the coating to infinite coating
the coating, the energy consumed in substrate deformation is also in- thickness (Fig. 11b).
cluded in the work done by the indenter. He proposed ABH in Fig. 10 as Chen and Bull [45,51] extracted the fracture energy U of a coating
the fracture energy U of the coating. In Fig. 10, ABEF represents the from the curve of total work Wt versus displacement D (see example
total work of the indenter during circumferential cracking and Fig. 12). First, the initial Wt vs. D curve is extrapolated from the crack-
ing start point A to the cracking end point C. Then Wt vs. D curve after
cracking is extrapolated back to the cracking start point. Vertical Wt
differences AB and CD are thus obtained. AB represents the work dif-
ference consumed in the elastic–plastic deformation of the coating/
substrate system before and after the coating fracture, and CD is the
total work done during the cracking. The difference between CD and
AB is thus deemed the fracture energy U.
Displacement-controlled nanoindentation of thin ceramic coat-
ings with a sharp indenter (cube corner tip with radius of 40 nm
when new) was extensively investigated by Chen and Bull [45,51].
Displacement-controlled indentation was supposed to be more sensi-
tive to the coating cracking because the load drop at coating fracture is
unambiguously related to the loss of the contact of the indenter with
the coating/substrate system. On the contrary, in addition to the indent-
er movement due to the loss of contact, there is an additional movement
of the indenter due to the deformation of the coating/substrate system
at the fracture load. Fig. 13a shows a typical load–displacement curve
of a displacement-controlled nanoindentation conducted on a 400 nm
TiOxNy coating on a glass substrate, in which the load jump between B
and C is associated with the radial through-thickness cracking of the
coating [45]. The Wt vs. D method was used to obtain the fracture energy
U and the fracture toughness was obtained according to Eq. (12).
Fig. 9. Schematic illustration of the boundaries of the irreversible work Wirr at the pla- The fracture behavior of a thin hard coating in nanoindentation as
teau in a nanoindentation load–displacement curve [47]. described by Li et al. (Fig. 8a) [34] and Malzbender et al. [49] is the
S. Zhang, X. Zhang / Thin Solid Films 520 (2012) 2375–2389 2381

a 300
a 2500
Chipping
250
Radial 2000
200
cracking Delamination

Load (µN)
150 1500

100
1000
50

0 500
0 0.1 0.2 0.3

b 300
100 200 300 400
Depth (nm)
250

200
b

150

100
2000
50
1500
0
0 0.1 0.2 0.3 0.4 0.5 0.6 1000

500
Fig. 11. (a) Energy irreversibly dissipated during indentation as a function of the peak
load applied during the indentation [49]; (b) the energy irreversibly dissipated during
indentation as a function of the inverse coating thickness t [50].

basis for the energy-based nanoindentation methodology. After radial


cracking, delamination and buckling, it is the circumferential through- 0.5 1 1.5 2
thickness cracking and spallation that results in a step in the load–
displacement curve which is used to extract the fracture energy U of Fig. 13. Displacement-controlled nanoindentation of a 400-nm-thick TiOxNy coating on
the coating. However, not only the circumferential cracking and spall- a glass substrate. In (a), position A is where plastic deformation of the softer substrate
ation, but also radial cracking of the coating [52–54], delamination of starts; points B and C are the start point and end point of through-thickness cracking; D
and E are the start point and end point of interfacial fracture. The circle in (b) marks an
the interface [55–56], cracking or spallation of the brittle substrate area of uplift associated with interfacial fracture [45].

5
[52,57], and even the dislocation nucleation and phase transformation
of the substrate material [58] induce a step in the loading curve of a
4 nanoindentation. These steps may overlap in some cases. For example,
the catastrophic delamination of a compressively stressed coating
after buckling overlaps with the circumferential cracking and spall-
3 ation that follows. This can be explained by the following one-
dimensional blister model of a coating.
The driving force (energy release rate of the interface) Gi of the in-
2 terfacial delamination after buckling is [59–61]
 2

Gi σ
¼ m 1− c ; ð14Þ
1 G0 σr

where G0 = (1−υ)tσr2/E and m = [1 + 0.9021(1−υ)] − 1; σr is the re-


0 sidual stress of the coating, and
0 0.5 1 1.5 2 2.5 3 3.5
 2
E t
σc ¼ 1:2235 ð15Þ
1−υ2 b
Fig. 12. Schematic illustration extrapolating the total work vs. displacement curve be-
fore and after cracking to determine the fracture dissipated energy CD–AB. Here, the
points A and D are the start and end points of the excursion in the measured work is the buckling stress; t is the coating thickness, and b is the radius of
vs. displacement curve [45]. the delaminated zone.
2382 S. Zhang, X. Zhang / Thin Solid Films 520 (2012) 2375–2389

Eq. (14) is schematically represented by Fig. 14, where Γi(ψ) is the


fracture toughness of the coating/substrate interface. Given an initial-
ly delaminated region of width 2bi, the coating will buckle at σr = σc.
The blister (buckled coating) would then spread dynamically when σr
reaches σ* (where Gi = Γi(ψ)), and would be arrested at b = b* (where Advancing
Gi = Γi(ψ). The buckling also favors cracking and spallation of the crack front
coating because a tensile stress in the coating on the inner side near
the edge is induced after bending. When the driving force Gf for y
cracking of the coating satisfies the equation
t

Gf Γf
N ; ð16Þ
Gi Γi ðψÞ

where Γf is the fracture toughness of the coating, the coating cracks


and spalls away from substrate at a particular angle [62]. Both the dy-
namic processes, i.e., the interfacial delamination and the cracking
x
and spallation of the coating, blend together.
More fundamentally, the fracture toughness should be obtained
from the energy release rate (or stress intensity factor) as catastrophic
fracture starts near equilibrium. (With reference to Fig. 14, this would Fig. 15. Three-dimensional channeling of a crack across a thin bonded coating [66].
be at the intersection of the vertical line at bi and the horizontal line at
“1”). In Fig. 14, let A be the area under the curve and above line “1”, the
fracture toughness obtained from the spallation process would then
be equivalent to A/(b* − bi); obviously this grossly overestimates the where
energy.
!
A more recent paper [63] scrutinized, from extensive published σ
data, the steps and the coating thicknesses, and concluded that the g ¼ g α; β; ; ns ;
σsy
steps are formed due to loss of contact of the indenter with the sample.
Upon catastrophic fracture of the coating, the indenter undergoes
in which σsy and ns are the yielding stress and strain hardening expo-
freefall of a distance approximately equal to the thickness of the coat-
nents of the substrate; and α and β are Dunders parameters describ-
ing. The size of such a step has no logical relationship with the energy
ing the elastic mismatch between the coating and the substrate:
dissipation that fractures the coating.

3.3. Toughness evaluation from channel cracking E −Es 1 μ ð1−2νs Þ−μs ð1−2νÞ
α¼ and β ¼ ;
E þ Es 2 μ ð1−νs Þ þ μs ð1−νÞ
Channel cracking is “through-thickness cracking” in which the
coating is cracked all the way through to the substrate as the crack where Es and νs are the elastic constants of the substrate, respectively,

propagates. The “through-thickness” characteristic is maintained dur- μ = E/2(1 + ν) denotes the shear modulus, and E ¼ E= 1−ν2 is a
ing crack propagation, forming a channel-like crack (Fig. 15). In tensile plane strain tensile modulus.
loading, as the crack length reaches approximately three times the In Eq. (17), the substrate effect is contained in g. Studies [64,66] of
coating thickness, the channel crack propagates at steady state until g indicate that a ductile substrate promotes channel cracking (i.e., at
complete fracture [64]. larger g, as can also seen in the ratio σσsy in the definition of g, ductile
Taking into consideration the substrate constraint on coating materials have much smaller yielding stress than brittle materials)
cracking, the stress intensity factor of the coating can be expressed and thus requires less stress to reach KI in Eq. (17).
as [61,64–68] For a thin ceramic coating on a ductile substrate, bending of the duc-
tile substrate causes channel cracking of the coating. Thus multi-strain
!1=2 flexure tests [69–70] and sphere indentation tests [67–68] have been
2
1−ν
KI ¼ σ πtg ; ð17Þ proposed for the fracture toughness of this type of coating/substrate
2
system.
A multi-strain flexure test [69–70] is illustrated in Fig. 16. A ce-
ramic coating is deposited on a ductile (metallic) substrate and the
coating patterned into strips. The sample is then placed under flexure
such that the ceramic coating strips are on the side surface of the
bending beam, and the strips are aligned along the beam axis. During
bending, a linear strain gradient is induced in the beam from the bot-
tom to the top: tensile strain on the top, compressive strain at the
bottom, and zero strain along the neutral plane. Thus, coating strips
at different positions are subjected to different strains. Coating strips
with strains larger than a critical value fracture. As such, the critical
strain can be indentified and the critical stress is thus obtained from
the stress–strain relationship (Hooke's law, assuming the ceramic
coating fractures in purely elastic deformation). Inserting the critical
stress in Eq. (17) yields the fracture toughness of the coating.
In sphere indentation, a spherical indenter of large radius is
Fig. 14. Schematic illustration of instability analysis of a one-dimensional blister [61]. indented into the coating to cause circular cracking (Fig. 17) [67–68].
S. Zhang, X. Zhang / Thin Solid Films 520 (2012) 2375–2389 2383

the yielding strain and hardening exponent of the ductile substrate.


The terms m1 and m2 are defined as:

  0:14
m1 εsy ¼ 1:45 þ
εsy
!
  1
m2 εsy ; ns ¼ ½1466−118ns  þ ½−22:7 þ 1:8ns 
εsy
!2
1
þ ½0:075−0:003ns  :
εsy

Once the critical strain is identified, the critical stress is obtained


through Hooke's law, thus Eq. (17) yields the ceramic coating's frac-
ture toughness. Expression (18) is suitable for most metallic sub-
strates [67].
The parameter g in Eq. (17) describes the constraint of the sub-
strate on the channel cracking of the coating. It is very complex for
ductile substrates [66], which hinders its application. In practice, it is
difficult to make coating strips on a metallic substrate by lithography.
In the case of the sphere indentation test, accurately locating the first
crack on the unloaded impression is a problem.
For thin hard coatings deposited on rigid (ceramic) substrates,
nanoindentation with a sharp edge indenter can be used to generate
radial channel cracks [19,57], as illustrated in Fig. 18. A hemispherical
plastic zone is generated under the contact at the beginning of inden-
tation; with increasing load, the plastic zone expands further and its
Fig. 16. A multistrain specimen and test configuration [70].
hemispherical shape changes upon impinging with the substrate.
The radial cracks emanate from the sharp corners. With further load-
ing, the plastic zone transforms to cylindrical and the radial cracks be-
come channel cracks (Fig. 18b) [71–72].
The strain of the coating under the indenter is axisymmetric and is a According to the rigid substrate hypothesis, the indented volume
function of the location (r), as given by Eq. (18) [21], of the coating material is solely accommodated via deformation of

εr   r    r 3
¼ m1 εsy þ m2 εsy ; ns ; ð18Þ
εsy D D a
Plastic zone
where εr is the strain in the radial direction; r and D are the radius of im-
pression and sphere indenter diameter respectively; and εsy and ns are Radial crack

Film

Sphere
Substrate

a Film
b
r
Plastic zone
Substrate
Impression Channel
crack

Film

Substrate
Circumferential
cracks
Fig. 18. (a) Schematic cross-section of indentation-induced partial-penetration radial
fracture in a mechanically-thick coating. When the coating is thick compared to the
plastic zone, the plastic zone is spherical in shape and radial cracks are seen as surface
traces. (b) Schematic cross-section of indentation-induced channel cracking in a me-
Fig. 17. The sphere indentation test: circumferential cracks develop within the indent chanically thin coating. Here, the plastic zone is cylindrically shaped due to the con-
[67]. straint of the substrate and the channel cracks extend through the coating [71–72].
2384 S. Zhang, X. Zhang / Thin Solid Films 520 (2012) 2375–2389

driving or retarding force. σr results in a stress intensity factor of


the form

1=2
Kr ¼ ψ′σr tf ; ð21Þ

where ψ′ is a constant that depends on the stiffness mismatch be-


tween the coating and the substrate [61,66]. At equilibrium, the frac-
ture toughness can be obtained by summation of Eqs. (19) and (21).

4. Microtensile testing of fracture toughness for standalone thin


films

Uniaxial tensile testing has been established for the measurement


Fig. 19. SEM image of a coating fracture in tetrahedral amorphous carbon (ta-C). The of fracture toughness [7–8]. In a uniaxial tensile test with a central
coating thickness is 248 nm [71]. crack, the stress intensity factor is
pffiffiffiffiffi
KI ¼ σ πl; ð22Þ
the coating. This requires a substrate much harder and tougher than
the coating [73]. Otherwise, the plastic zone may extend into the sub- where σ is the sample stress, and l is half the length of the central
strate [58] or, even worse, cause extensive substrate deformation [74]. crack. For a tensile testing specimen with an edge crack, the stress in-
Assuming there is no deformation in the substrate, the stress intensity tensity factor becomes
factor of indentation-driven channel cracking is derived as [61,75]
pffiffiffiffiffiffi  a 
 1=3
 KI ¼ σ πaf : ð23Þ

Ef Hf2 a2 W
KI ¼ λV : ð19Þ
tf c1=2
The sample dimensional function f ða=W Þ ¼ 1:12−0:23ða=W Þþ
10:55ða=W Þ2 −21:72ða=W Þ3 þ 30:41ða=W Þ4 , in which a is the length
The subscript f′ refers to “film” or coating properties and λ is ap-
of the edge precrack and W is the width of the gauge region. Eq. (23)
proximately 0.013 for the Vickers geometry and 0.016 for the cube-
is valid for a/W ≤ 0.6 [76].
corner geometry. a is the radius of the indentation, and c is the
The concept of micro-tensile testing is straightforward for mea-
crack length. For a well-developed channel crack, Eq. (19) requires
suring the fracture toughness of thin films according to Eqs. (22)
that the crack length is larger than three times of the film thickness
and (23). However, it is very challenging to prepare freestanding
as shown in Fig. 19. The parameter V* is used to exclude the portion
samples with micro-scale size and then conduct tensile tests on
of the indented displaced volume accommodated by the substrate
them. Notable progress has been made in micro- and nano-scale ten-
when the indenter tip penetrates through coating [71],
sile testing in recent years [5,77–88]. Photolithographic techniques
8 are used in the preparation of freestanding films. According to classi-
>
> 1 hp ≤ tf
<  3 cal fracture toughness measurements, atomically sharp precracks of

V ¼ hp −tf : ð20Þ known lengths are required. Vickers indentations and focused ion
>
> hp N tf
: 1− beams are most commonly used to produce precracks in the film.
h3p
Loading of the precracked standalone films can be very delicate and
hp refers to indentation depth and tf is the coating thickness. Re- difficult. Quite a few methods have been proposed: the inchworm ac-
sidual stresses σr from deposition acts as an additional crack tuation by Chasiotis et al. [85], membrane deflection by Espinosa et al.

Fig. 20. Microscale fracture specimen preparation and testing: (a) specimen before indentation of the SiO2 substrate, (b) specimen with edge pre-crack after indentation, (c) free-
standing specimen with edge precrack after substrate removal (release), and (d) fracture of specimen at applied force P [84].
S. Zhang, X. Zhang / Thin Solid Films 520 (2012) 2375–2389 2385

4.1. Inchworm actuation

The inchworm actuation method [87] is illustrated in Fig. 20. The


‘dog-bone’ shape film is produced lithographically. An edge pre-
crack is fabricated by indentation of the adjacent free substrate region.
To facilitate griping of the sample, one end of the ‘dog-bone’ is not re-
leased from the substrate, while the other end is freestanding. UV glue
and electrostatic suction are combined to provide bonding of the free-
standing end of the ‘dog-bone’ to a loading beam. The tensile load is
applied to the film via an inchworm actuator. The resolution of the ac-
tuator is 4 nm and the load cell has an accuracy of 10 − 4 N. The fracture
toughness is obtained according to Eq. (23) given the critical stress at
fracture.
The technique was used successfully in the fracture toughness
measurement of diamond-like carbon (DLC) and polycrystalline sili-
con films [84,86,91].

4.2. Membrane deflection

In the membrane deflection method [88], the film to be tested is


deposited on a silicon wafer and patterned into strips using litho-
graphic techniques. The gauge section of each film strip is made free-
standing by etching away the silicon wafer material from the backside
using techniques for micro-electromechanical systems (MEMS)
(Fig. 21). The loading is accomplished vertically using a nanoindenter
with line-load tip at the middle of the free standing span (Fig. 22). A
microscope interferometer positioned directly below the specimen
measures the deflection Δ of the film from the fringes generated as a
result of phase differences of the monochromatic light reflecting off
the film after traveling different path lengths. The angle θ that the
film moves upon deflection is given as

Δ
tan θ ¼ ; ð24Þ
LM

where LM is the initial length of the film strips. The tensile load PM and
the stress σ in the film are obtained through Eqs. (25) and (26)

PV
PM ¼ ð25Þ
2 sin θ
Fig. 21. (a) Schematic representation of three general microfabrication steps used to
process specimens; (b) optical image of three Au membranes showing characteristic PM
σ¼ : ð26Þ
dimensions. LM is half the membrane length and W is the membrane width [88]. A

PV is the vertical nanoindentation load on the film and A is the cross-


[88], tension by residual stress by Kahn et al. [82–83,89], bulging of sectional area of the film in the gauge section.
films by Xiang et al. [80–81], and the most recent substrate macroten- At fracture of the film, the fracture toughness is calculated accord-
sion by Zhang and Zhang [90]. The key points of these methods are ing to Eq. (23). This method has been used for ultrananocrystalline di-
described below. amond films [92], diamond-like carbon (DLC) films, silicon nitride

Gauge area Membrane Line-load tip Silicon substrate

Mireau
microscope
objective

Fringe pattern Fringe pattern

a) Before loading b) After loading


Fig. 22. Schematic drawing of the membrane deflection experiment (MDE) setup and monochromatic images of the bottom side of a membrane in (a) the unloaded state and
(b) under load [93].
2386 S. Zhang, X. Zhang / Thin Solid Films 520 (2012) 2375–2389

(Si3N4) films [93–94], and single crystal silicon carbide (3C-SiC) [87], is freestanding in the center while ends still adhere well to the sub-
as well as gold, copper, and aluminum films [88,95–96]. strate as shown in Fig. 23b). A sharp precrack is produced by indenta-
tion in the film bridges before they are freestanding from substrate
4.3. Tension by residual stress (Fig. 23a, c). The film bridges are stressed automatically due to
unleashing of the residual stress. The stress intensity is related to
This is an ingenious way of loading: the residual tensile stress in a the initial crack length as shown by the K versus a curves in
thin film is used to serve as the loading to fracture the film in a frac- Fig. 23d. The film bridges crack if the stress intensity factor is above
ture toughness measurement [82–83,89]. The film to be tested is the fracture toughness. Thus, the fracture toughness lies between
made into bridges with lithographic technologies (a film strip that the stress intensity factors of the broken and unbroken bridges

Fig. 23. Images of film bridges used to measure fracture toughness and stress corrosion. (a) Schematic top view showing the dimensions. (b) Schematic side view. (c) SEM images of
a 60-μm-wide beam with an indentation placed near its center, a higher magnification SEM of the area near the indent showing the precrack traveling from the substrate into the
beam. The indent was made on the SiO2 release layer, which was subsequently removed by the HF etching. (d) Plot of stress intensity K versus crack length a for polysilicon film
bridges. The solid lines show the relations between K and a for three values of residual stress. The dotted line is the fracture toughness KIC determined from these data [89].
S. Zhang, X. Zhang / Thin Solid Films 520 (2012) 2375–2389 2387

(dotted line in Fig. 23d). For application of this method, the residual a
stress must be tensile (not compressive) and the magnitude should
Focused ion beam
only be in the range of a few tens of MPa.

4.4. Bulging of films Film

The bulge test was originally proposed for the accurate measure- Si
ment of elastic properties of freestanding films [97], and was later
used in the measurement of fracture toughness [80–81,98]. In the b
bulge test, a rectangular “window” of the silicon substrate is etched
away to reveal the film to be tested (see Fig. 24a). A focused ion
beam is used to prepare a precrack length 2l in the film along the lon-
ger side at the middle of the window (Fig. 25). A uniform air or water
pressure is applied at the window to “bulge” the film as shown in Stress
Fig. 24b. If the window's length over width ratio is greater than
four, the stress σ and strain ε of the film will be uniformly distributed
across the width of the bulged film [80] (Fig. 24b):
 
p a2 þ h2
σ¼ ð27Þ
2ht

2 2   Stress
a þh 2ah
ε ¼ ε0 þ arcsin 2 −1; ð28Þ
2ah a þ h2

where p is the applied pressure, h is the membrane deflection, t is the


Fig. 25. (a) Schematic illustration of the micro-fabrication of a precrack of length 2l at
film thickness, 2a is the width of the membrane, and ε0 is the residual
the center of a freestanding membrane using a focused ion beam and (b) SEM image of
strain in the film. a typical precrack in an AlTa coating on a silicon wafer substrate. The arrows indicate
At critical pressure, Eq. (27) gives rise to the critical stress σC the transverse direction of the membrane [81].
when the film fractures. Inserting the critical stress σC into Eq. (22)
yields the fracture toughness of the film.

4.5. Macrotension of substrate

A recently proposed method is microtensile testing of film micro-


bridges via macrotension to a substrate [90]. In this method, the film
is deposited on a rectangular silicon wafer substrate, in which an ini-
tial edge crack is introduced using a diamond cutter with a manual
application of a small force. After film deposition, a section of the
film ahead of the substrate crack is patterned into strips as shown
in Fig. 26. Precracks on each film strip are made with Vickers indenta-
tion into the adjacent substrate region. The film strips are then re-
leased from the substrate by etching away a ZnO sacrificial layer to
form film microbridges; i.e. the middle of the strip is released while
both ends are still affixed to the substrate. As the surface tension of
the etchant would fracture the microbridges easily when the sample
is taken out of the liquid, a sample holder is made to allow testing

P=0

Fig. 26. Schematic of the testing configuration for the substrate macrotension tech-
P >0 nique: a rectangular silicon wafer substrate containing an edge crack and two pin-
holes; a series of film strips just ahead of the tip of the substrate crack. Just before test-
Fig. 24. Schematic illustration of the bulge test for a section of a long rectangular mem- ing, the film strips are released from the substrate through etching of a sacrificial layer
brane: perspective views of the freestanding film, (a) before and (b) after a pressure P between the film and the substrate; upon loading, the substrate crack extends in a sta-
is applied [81]. ble manner and travels beneath film bridges [90].
2388 S. Zhang, X. Zhang / Thin Solid Films 520 (2012) 2375–2389

in water. On testing, a displacement controlled loading is applied to is simple, but the assumption of rigidity of the substrate usually
the substrate by manually dialing a micrometer. The tensile loading does not apply.
opens the substrate crack beneath the microbridges, causing the brid- Circumferential cracking and spallation take place during nanoin-
ges to fracture (Fig. 26). dentation of hard, thus brittle, coatings on ceramic substrates. If the
The film strain ε is measured through the extension δ of the film energy released per fractured area (U/A) is obtained, the fracture
during testing, toughness of the coating is calculated through Eq. (12):

δ " #1=2
ε¼ : ð27Þ EU
L0 KC ¼   :
1−ν2 A

L0 is the original length of the microbridge before loading. The exten-


sion δ of the microbridge is measured by the extension of the substrate Many authors obtain the fracture energy U from extrapolation of
crack opening, which gives rise to a critical stress through Hooke's law, the load–displacement curve in which a step appears upon fracture.
σ = Eε, as the ceramic film is assumed to fracture elastically. The frac- However, extraction of U from the step is controversial.
ture toughness is then calculated according to the Eq. (23).
The first advantage of the tension on substrate method lies in the 5.2. Thin films
fact that expensive equipment such as a focused ion beam is not re-
quired. Only a precision micrometer is needed to carry out the test. The most straightforward and reliable way of testing a thin film is to
Technically, using a ZnO release layer as a sacrificial layer (and thus apply tension directly to the film when it is “freestanding”. A number of
0.25% HCl as the etchant) instead of a SiO2 layer (thus toxic HF as “microtensile” methods have been used: inchworm actuation, mem-
the etchant) not only reduces the toxicity, but also allows testing of brane deflection, tension by residual stress, bulging, and the most re-
almost all ceramic films and even metallic films. The shortcoming of cent “macrotension of substrate”. In all these method, the key is p the
ffiffiffiffiffi
the method is its requirement of testing in water (to circumvent the determination of the critical stress σ of the film; then KI ¼ σ πl
pffiffiffiffiffiffi
surface tension problem of the liquid etchant). Eq. (22) for a central crack or KI ¼ σ πaf ða=W Þ Eq. (23) for an edge
crack characterizes the fracture toughness. The formulation in micro-
5. Summary tensile testing is indeed very simple, but the difficulty lies in making
the film freestanding, introducing a sharp precrack in the film, and
This article reviewed recent advances in fracture toughness mea- clamping the film and applying a minute testing force. Technically, all
surements for hard coatings and thin films. these are difficult to accomplish and usually require specific and dedi-
cated apparatus.
5.1. Hard coatings The “macrotension of substrate” method developed recently pro-
vides an extremely simple alternative, in which fracture forces are ap-
For a hard coating well bonded on the substrate, the most com- plied to freestanding “microbridges” through macrotension of the
mon qualitative methods used include indentation plasticity and substrate via a simple micrometer. This method cleverly solves the
scratch resistance; quantitatively, different methods are used based problems of clamping a freestanding film and applying minute forces
on the type of cracking patterns upon indentation: radial cracking, on it.
channel cracking, and circumferential cracking and spallation.
The most common radial cracking method consists of the ultralow Acknowledgments
load indentation of the coating and measuring the lengths of resulting
radial cracks. Once the length c is measured, the fracture toughness is This work was supported by Project No. T208A1218 of the Minis-
calculated via Eq. (7): try of Education, Singapore, and partly by Project No. 51001084 of the
National Natural Science Foundation, China.
 1=2  
E P
KC ¼ α 3=2
: References
H c
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