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Elastic-plastic stress analysis of a Zener-Stroh crack paralleling to the interface of a coating-substrate system has been carried out in this work.  The sum of the Burgers vectors of the climb and the glide dislocations along the crack line account for the stress field around its blunt tip where dislocation enters, and the sharp tip where crack propagates. Firstly, Gauss-Chebyshev quadrature technique is applied to solve the governing equation of dislocation density functions constrained by load-free crack faces. When taking plasticity into account at both crack tips where stresses are high, the generalized Irwin plastic zone correction is recommended. Plastic zone size (PZS) for both tips and crack tip opening displacement (CTOD) for the sharp tip are then obtained. The effects of coating thickness, crack depth, material mismatch and dislocation loads ratio onto PZSs and CTOD have been analyzed in detail.

computation