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Abstract During drying, liquid‐applied particulate coatings develop stress and are consequently prone to stress‐induced defects, such as cracking, curling, and delamination. In this work, the stress development and cracking of coatings, prepared from aqueous silica and zinc oxide particle suspensions, were characterized using cantilever beam deflection with simultaneous imaging of the coating surface. Drying uniformity was improved and lateral or edge‐in drying was discouraged by using thin silicone walls around the perimeter of the cantilever. Coatings prepared from larger monodisperse silica particles (D50∼ 0.9 µm) dried uniformly but had a high critical cracking thickness (>150 µm) that prevented simultaneous study of stress development and cracking. Coatings prepared from smaller silica particles (D50∼ 0.3 µm) cracked readily at low thicknesses but exhibited edge‐in drying that complicated the stress measurement data. This drying nonuniformity was connected to the potential for these small particles to accumulate at the coating surface during drying. Hence, the selection of particle size and density was critical to drying uniformity when characterizing stress development and cracking. Coatings prepared from suspensions of zinc oxide particles (D50∼ 0.4 µm) were well‐suited for these studies, with uniform drying stress peaking at ∼1 MPa. Characteristic features in the stress development data above and below the critical cracking thickness (53 µm) were identified, demonstrating that cantilever beam deflection is a useful tool for studying the effectiveness of crack mitigation methods and the fundamentals of coating fracture during drying.
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This content will become publicly available on March 1, 2026
Bioinspired SiC/Chitosan Impact Resistant Coatings
Abstract Routine high strain rate impacts from the surrounding environment can cause surface erosion, abrasion, and even catastrophic failure to many structural materials. It is thus highly desirable to develop lightweight, thin, and tough impact resistant coatings. Here, inspired by the structurally robust impact surface of the dactyl club of the peacock mantis shrimp, a silicon carbide and chitosan nanocomposite coating is developed to evaluate its impact resistance as a function of particle loading. High strain rate impact tests demonstrate that coatings with 50% and 60% SiC have optimal performance with the greatest reduction in penetration depth and damage area to the substrate. Post‐impact analysis confirms that these concentrations achieve a balance between stiffness and matrix phase continuity, efficiently dissipating impact energy while maintaining coating integrity. The addition of SiC particles helps dissipate impact energy via interphase effects, particle percolation, and frictional losses due to particle jamming. The formation of these stress paths is also modeled to better understand how the addition of particles improves coating stiffness and the stress distribution as a function of particle loading. These findings highlight the potential of bioinspired materials and their promise to promote innovation and breakthroughs in the development of resilient multifunctional materials.
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- Award ID(s):
- 2011967
- PAR ID:
- 10590625
- Publisher / Repository:
- Wiley
- Date Published:
- Journal Name:
- Advanced Functional Materials
- Volume:
- 35
- Issue:
- 11
- ISSN:
- 1616-301X
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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