Conventional numerical approaches for simulating fracture in thin films used in bioengineering applications frequently neglect the complex and heterogeneous morphology of the deposited layers. This simplification, while computationally convenient, often results in inaccurate predictions of mechanical behavior, particularly in terms of fracture initiation and propagation. Such limitations can introduce substantial uncertainties and potential risks during the design, optimization, and functional deployment of thin-film-based systems, especially in sensitive biomedical applications where reliability and structural integrity are critical. In this study, a comprehensive and novel numerical framework is developed to systematically investigate fracture evolution in pulsed laser-deposited (PLD) titanium nitride (TiN) thin films subjected to mechanical loading conditions. As a representative configuration, a TiN coating deposited on an aluminum (Al) substrate is considered, reflecting a commonly used material system in engineering and bioengineering contexts due to its favorable mechanical and surface properties. To accurately characterize the constitutive behavior of the materials involved, nanoindentation experiments were conducted on both the Al substrate and the TiN/Al composite system. These experiments provided high-resolution load–displacement data, which were subsequently processed using an inverse analysis methodology to extract the corresponding stress–strain relationships. This approach enabled a reliable determination of the flow stress behavior of the individual components as well as the coated system, ensuring that the numerical model is grounded in experimentally validated material properties.
F Nethercot (Sun,) studied this question.