New technique for determining the critical loads of a thin coating on a tool–steel substrate by considering the initiation of cracks in the coating

In this article, a mathematical algorithm is derived to accurately determine the critical load of indentation for the initiation of cracks on the surface of a hard coating on a soft substrate, based on the measurement of the diameter of circumferential cracks in micro-indentation impressions. The critical load required for the initiation of the first crack predicted using this technique is shown to be in good agreement with experimental results, indicating the feasibility of the technique proposed. The rationality of the approach proposed was further explored by investigating the fracture mechanism of the surface in a multilayer-coated surface using a finite element model, which was developed with the parameterised modelling approach, in combination with the cohesive-zone model.