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Surface stress can initiate environment-assisted fracture in metals

Anirudh Udupa1, Debapriya Pinaki Mohanty2, Tatsuya Sugihara3, James B. Mann2, Ronald M. Latanision4,5,6, and Srinivasan Chandrasekar2

  • 1Department of Mechanical Engineering, Indian Institute of Technology Madras, Chennai, Tamil Nadu 600036, India
  • 2Center for Materials Processing and Tribology, Purdue University, West Lafayette, Indiana 47906, USA
  • 3Department of Mechanical Engineering, Osaka University, Suita, Osaka 5650871, Japan
  • 4Department of Materials Science and Engineering, MIT, Cambridge, Massachusetts 02139, USA
  • 5Exponent Inc., Natick, Massachusetts 01760, USA
  • 6College of Engineering, Purdue University, West Lafayette, Indiana 47906, USA

Phys. Rev. E 109, L023002 – Published 12 February, 2024

DOI: https://doi.org/10.1103/PhysRevE.109.L023002

Abstract

Controlling environmental effects in surface plasticity/fracture of metals is of interest for areas as diverse as manufacturing processes, product performance, and structural safety. The key to controlling these effects is understanding the effect of adsorbates on surface energy (γ) and surface stress (f). While γ has been well studied, the role of surface stress has received much less attention. We characterize surface stress induced in metals by adsorption of organic monolayers. Linear alkanoic acids of varying chain length (3–18) are deposited by molecular self-assembly onto one side of an aluminum cantilever, several centimeters in length. The surface stress is estimated from in situ measurement of the cantilever deflection. We find that the organic adsorbates induce large surface stress of −4 to +30N/m. Furthermore, we show that f may be tuned by varying adsorbate-molecule chain length. The stress data explain beneficial embrittlement of metal surfaces by organic adsorbates in cutting and comminution processes, and point to a critical role, hitherto ignored, for f in environment assisted cracking (EAC) phenomena. Our results suggest opportunities for utilizing controlled environment-assisted fracture as an aid—fracture as a friend—to enhance material removal processes, apart from using surface stress itself as an experimental probe to explore various manifestations of EAC.

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