Local delamination on heavily deformed polymer–metal interfaces: evidence from microscopy

In this work the microstructure of interfaces present in heavily bi-axially deformed polymer-coated metal is studied. Cross sections of deformed polymer-coated steel are prepared using several polishing strategies, including the use of focused ion beam, and are imaged using optical microscopy and scanning electron microscopy. We find that the interfaces show significant details right down to the smallest scale observable with the preparation techniques used of about ~10 nm. Local delamination events at these deformed interfaces are observed and are found to be preferentially associated with overhanging parts on the interface. Overhanging parts are frequently observed, but only below a certain length-scale on the interfaces that are otherwise found to be self-affine up to a certain correlation length. The smallest detail includes the tail of the size distribution of the overhanging features. Together this suggests that the physical mechanisms determining the formation of critical features for adhesion operate at sub-grain level as well as at grain level.