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Despite these advantages, the operational integrity of bi-layer architectures is frequently compromised by interfacial failure modes driven by mismatched elastic moduli, coefficients of thermal expansion (CTE), and processing-induced residual stresses. These vulnerabilities often manifest as delamination, fatigue cracking, or environmental degradation, leading to premature structural failure. While recent research has explored isolated material pairs or specific mechanisms, a holistic synthesis that bridges fundamental mechanics across diverse sectors is currently absent. This review addresses this critical gap by providing a comprehensive, multi-disciplinary examination of bi-material interfaces. We categorize prevalent failure origins, from thermo-mechanical stress concentrations to hygrothermal aging, and provide an evaluative framework for mechanical predictive methodologies, including Linear Elastic Fracture Mechanics (LEFM), Cohesive Zone Modeling (CZM), and Phase-Field Modeling (PFM). Furthermore, we assess state-of-the-art mitigation strategies, such as functionally graded interlayers, bio-inspired interlocking geometries, and advanced surface functionalization. By unifying experimental observations with computational frameworks, this work establishes a strategic roadmap for optimizing interfacial performance, offering researchers and practitioners a definitive guide to designing resilient, next-generation bi-material systems for high-performance applications.<\/jats:p>","DOI":"10.1177\/14644207261427056","type":"journal-article","created":{"date-parts":[[2026,3,11]],"date-time":"2026-03-11T19:09:13Z","timestamp":1773256153000},"update-policy":"https:\/\/doi.org\/10.1177\/sage-journals-update-policy","source":"Crossref","is-referenced-by-count":0,"title":["A comprehensive review of failures in bi-material interfaces: Mechanisms, prediction, and mitigation strategies"],"prefix":"10.1177","author":[{"ORCID":"https:\/\/orcid.org\/0009-0007-2019-1931","authenticated-orcid":false,"given":"Payam","family":"Maleki","sequence":"first","affiliation":[{"name":"Faculdade de Engenharia (FEUP), Universidade Do Porto"},{"name":"Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI), Rua Dr Roberto Frias, Porto 4200-465, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-7168-7079","authenticated-orcid":false,"given":"Alireza","family":"Akhavan-Safar","sequence":"additional","affiliation":[{"name":"Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI), Rua Dr Roberto Frias, Porto 4200-465, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-1933-0865","authenticated-orcid":false,"given":"Ricardo J.C.","family":"Carbas","sequence":"additional","affiliation":[{"name":"Faculdade de Engenharia (FEUP), Universidade Do Porto"},{"name":"Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI), Rua Dr Roberto Frias, Porto 4200-465, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-2750-8184","authenticated-orcid":false,"given":"Eduardo A.S.","family":"Marques","sequence":"additional","affiliation":[{"name":"Faculdade de Engenharia (FEUP), Universidade Do Porto"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-3272-4591","authenticated-orcid":false,"given":"Lucas F.M.","family":"da Silva","sequence":"additional","affiliation":[{"name":"Faculdade de Engenharia (FEUP), Universidade Do Porto"}]}],"member":"179","published-online":{"date-parts":[[2026,3,4]]},"reference":[{"key":"e_1_3_3_2_2","doi-asserted-by":"crossref","first-page":"549","DOI":"10.1016\/j.compstruct.2017.03.071","article-title":"Marques EAS, da Silva LFM. 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