Single-Impact Failure of Multi-Layered Automotive Coatings: A Finite Element-Based Study

Abstract

Automotive coatings are a multi-layered polymer composite structure whose impact resistance is closely related to the appearance and safety of a vehicle. Since experimental methods are of high cost and poor repeatability, in our work, a finite element model is developed for the single-impact failure of automotive coatings. In this model, a multi-mechanism damage model and a large deformation cohesive zone model are employed to account for the polymer-ply and interlaminar failures of the coating, and some rate-dependent material models are adopted to capture the effect of impact velocity. The simulated results indicate that the proposed model can reproduce the failure patterns of automotive coatings well. In addition, the impact failure mechanisms of the coating are revealed. Numerical findings show that both brittle and ductile failures are found in the coating and there are three stages for the propagation of the delamination crack. Finally, we numerically investigate the effects of primer mechanical properties, i.e., Young’s modulus, yield strength, and re-hardening modulus, on the impact resistance of automotive coatings. Our work is helpful to the design of coating, which can improve the impact resistance of automotive coatings.