Abstract
The study of fracture mechanics is usually within the paradigm of a failure mode that needs to be avoided. However, both in nature and in modern technology, there exist several situations where an ability to fracture is essential. In this work, we consider the problem of machining highly ductile and strain-hardening metals, such as annealed Cu, Al and Ta. These metals are known by the moniker “gummy metals” due to the large forces and poor surface finish associated with machining them. We investigate a chemo-mechanical technique involving adsorption of organic monolayers on the metal surfaces that causes the metals to become relatively brittle. This transition from ductile to brittle results in > 50% drop in the cutting force and an order of magnitude improvement in the surface finish. Molecular dynamics simulations of the phenomenon show the organic monolayers impose a surface stress on the metal surface which results in arresting of the dislocations close to the surface. The results suggest that a deeper understanding of the underlying mechanism has implications in environment-assisted cracking, stress-corrosion cracking and hydrogen embrittlement.
Similar content being viewed by others
References
Adrian RJ (1991) Particle-imaging techniques for experimental fluid mechanics. Annu Rev Fluid Mech 23:89
Anderson TL (2017) Fracture mechanics: fundamentals and applications. CRC Press, College Station
Barenblatt GI (1962) The mathematical theory of equilibrium cracks in brittle fracture. Adv Appl Mech 7:8
Bateman PW, Fleming PA (2009) To cut a long tail short: a review of lizard caudal autotomy studies carried out over the last 20 years. J Zool 277(1):89
Bilby BA (1980) Tewksbury lecture: putting fracture to work. J Mater Sci 15:535–556
Brace WF, Paulding BW, Scholz C (1966) Dilatancy in the fracture of crystalline rocks. J Geophys Res 71(16):78
Buckman RW (2000) New applications for tantalum and tantalum alloys. JOM 52(3):89
Damme V, Hassani A, Abdalla AM, Hettiaratchi DRP, Reece AR (1969) The mechanics of root growth in granular media. J Agric Eng Res 8:267–283
Desikan R, Armel S, Meyer HM, Thundat T (2007) Effect of chain length on nanomechanics of alkanethiol self-assembly. Nanotechnology 18(42):89
Farrar CR, Worden K (1851) 2007, “An introduction to structural health monitoring. Philos Trans R Soc A 365:89
Fynn G, Powell W (1988) Cutting and polishing optical and electronic materials. Institute of Physics Publishing, Bristol
Gayko M, Wostefeld B, Wochnowski H (1973) Effect of sorption and reaction processes on the strength of metals and the action of sorptive dependent tribological properties on the kinetics of crushing. Zeitschrift Fur Phys Chemie 87(1):83–93
Gibbs JW (1906) The scientific papers of J Willard Gibbs. Longmans-Green, London
Gilman JJ (1961) The mechanism of surface effects in crystal plasticity. Philos Mag 6(61):8
Godin M, Williams PJ, Tabard-Cossa V, Laroche O, Beaulieu LY, Lennox RB, Grütter P (2004) Surface stress, kinetics, and structure of alkanethiol self-assembled monolayers. Langmuir 20(17):7090–7096
Griffith AA (1921) The phenomena of rupture and flow in solids, Griffith.Pdf. Philos Trans R Soc Lond 221:9
Hofacker M, Miehe C (2012) Continuum phase field modeling of dynamic fracture: variational principles and staggered FE implementation. Int J Fract 178:113–129
Janssen GCAM, Abdalla MM, van Keulen F, Pujada BR, van Venrooy B (2009) Celebrating the 100th anniversary of the stoney equation for film stress: developments from polycrystalline steel strips to single crystal silicon wafers. Thin Solid Films 517(6):89
Johnson KL, Kendall K, Roberts AD (1971) Surface energy and the contact of elastic solids. Proc R Soc Lond A 324(1558):301–313
Jorgensen WL, Maxwell DS, Tirado-Rives J (1996) Development and testing of the OPLS All-atom force field on conformational energetics and properties of organic liquids. J Am Chem Soc 118(45):8
Kamdar MH (1983) “Liquid metal embrittlement. Treatise Mater Sci Technol 25:361–459
Krishnan M, Nalaskowski JW, Cook LM (2010) Chemical mechanical planarization: slurry chemistry, materials, and mechanisms. Chem Rev 110(1):8
Latanision RM, Jones RH (1987) Chemistry and physics of fracture. Springer, New York
Lynch S (2012) Hydrogen embrittlement phenomena and mechanisms. Corros Rev 30:105–123
McMahon BW, Perez JPL, Yu J, Boatz JA, Anderson SL (2014) Synthesis of nanoparticles from malleable and ductile metals using powder-free, reactant-assisted mechanical attrition. ACS Appl Mater Interfaces 6(22):19579–19591
Merchant ME (1945) Mechanics of the metal cutting process -I. Orthogonal cutting and a type 2 chip. J Appl Phys 16(5):267–275
Oriani RA (1984) On the possible role of the surface stress in environmentally induced embrittlement and pitting. Scr Metall 18(3):265–268
Pawlik Ł, Phillips JD, Šamonil P (2016) Roots, Rock, and Regolith: biomechanical and biochemical weathering by trees and its impact on hillslopes: a critical literature review. Earth-Sci Rev 159:89
Rice JR (1968) A path independent integral and the approximate analysis of strain concentration by notches and cracks. J Appl Mech Trans ASME 35(2):8
Rice JR (2006) Heating and weakening of faults during earthquake slip. J Geophys Res Solid Earth 111(5):789
Rice JR, Thomson R (1974) Ductile versus brittle behaviour of crystals. Philos Mag A 29(1):73–97
Sanford R (ed) (1997) Selected papers on foundations of linear elastic fracture mechanics. SPIE, Bellingham
Scholz C (1990) Mechanics of Earthquakes and Faulting. Cambridge University Press, Cambridge
Shaw MC (1954) Metal cutting principles. M.I.T. Press, Cambridge
Sieradzki K, Newman RC (1987) Stress-corrosion cracking. J Phys Chem Solids 48(11):1101–1113
Solomon TWG (2002) Organic chemistry. Wiley, New York
Stoney GG (1909) The tension of metallic films deposited by electrolysis. Proc R Soc A 82(553):172–175
Tao YT (1993) Structural comparison of self-assembled monolayers of n-alkanoic acids on the surfaces of silver, copper, and aluminum. J Am Chem Soc 115(10):4350–4358
Udupa A, Sugihara T, Viswanathan K, Latanision RM, Chandrasekar S (2021) Surface-stress induced embrittlement of metals. Nano Lett 21(22):9502–9508
Udupa A, Viswanathan K, Saei M, Mann JB, Chandrasekar S (2018) Material-independent mechanochemical effect in the deformation of highly-strain-hardening metals. Phys Rev Appl 10(1):014009
Ulman A (1996) Formation and structure of self-assembled monolayers. Chem Rev 96(4):1533–1554
Vashishta P, Kalia RK, Nakano A, Rino JP (2008) Interaction potentials for alumina and molecular dynamics simulations of amorphous and liquid alumina. J Appl Phys 103(8):83504
Westwood ARC (1974) Tewksbury lecture: control and application of environment-sensitive fracture processes. J Mater Sci 9(11):1871–1895
Williams JE, Smart EF, Milner DR (1970) The metallurgy of machining. Part I: basic considerations and the cutting of pure metals. Metallurgia 81(483):3–10
Yeung H, Viswanathan K, Compton WD, Chandrasekar S (2015) Sinuous flow in metals. Proc Natl Acad Sci 112(32):9828–9832
Yeung H, Viswanathan K, Udupa A, Mahato A, Chandrasekar S (2017) Sinuous flow in cutting of metals. Phys Rev Appl 8(5):054044
Acknowledgements
This research was supported in part by NSF awards DMR 2104745 and PFI 2141180.
Author information
Authors and Affiliations
Contributions
AU and SC wrote the main manuscript text.AU, DPM, JBM, KV and JMD performed experiments.AU, DPM and JMD prepared figures.All authors reviewed the manuscript.
Corresponding author
Ethics declarations
Competing interest
The authors declare no competing interests.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Udupa, A., Mohanty, D.P., Mann, J.B. et al. Fracture, my friend: the cutting of gummy metals. Int J Fract (2024). https://doi.org/10.1007/s10704-024-00767-6
Received:
Accepted:
Published:
DOI: https://doi.org/10.1007/s10704-024-00767-6