The thermal stresses in a metallic thin film bonded to a ceramic coating on a metal substrate, generated by heat flux conditions in an engine, were studied. The film yields as a result of differential contraction and its thermo-plastic behavior is determined. Edge delamination of the film is related to the displacements of an interface edge crack between the film and ceramic. The effects of varying the surface roughness of the interface, the thickness of the film, the film material, the thermal expansion coefficients and the moduli of elasticity of the ceramic and metal on the stresses in the film and the crack are studied.

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