Microsample tensile testing of nanocrystalline metals

Comparative Study of the Tensile Properties of a Zircaloy-4 Alloy Characterized by Mesoscale and Standard Specimens

The accuracy and reliability of small-scale mechanical tests remain doubtful due to significant dependence of the obtained mechanical properties on specimen size. Mesoscale tensile tests with specimen sizes ranging from 10 μm to 1 mm are capable of obtaining bulk-like properties but are rarely applied to hexagonal close-packed metals. In this study, well-designed comparative tensile tests were carried out on a Zircaloy-4 alloy with a grain size of 4 μm using femtosecond laser-machined mesoscale specimens with a thickness of about 60 μm, sub-sized specimens with a thickness of about 1.3 mm, and standard specimens with a thickness of 4 mm. The quantitative results revealed that irrespective of the small specimen dimensions, the yield strength, tensile strength, and tensile ductility are only approximately 10.4%, 5.2%, and 13% lower than those of the standard specimens, respectively. This clearly demonstrates that the mechanical properties can be assessed with satisfactory accuracy by mesoscale tensile tests. The comparatively greater deviation of the yield strength at the mesoscale arises from the disappearance of yield point behavior, while the reduced tensile ductility is associated with the larger volume fraction of surface grains. The surface grains are characterized by more surface dislocation sources and deform with weaker constraints from neighboring grains, leading to smooth plastic yielding and slightly reduced strain hardening at the mesoscale.

Size Dependence of Grain Boundary Migration in Metals under Mechanical Loading

The greatly increased grain boundary (GB) mobility in nanograined metals under mechanical loading is distinguished from that in their coarse-grained counterparts. The feature leads to softening of nanograined materials and deviation of strength from the classical Hall-Petch relationship. In this Letter, grain size dependences of GB migration in nanograined Ag, Cu, and Ni under tension were investigated quantitatively in a wide size range. As grain size decreases from submicron, GB migration intensifies and then diminishes below a critical grain size. The GB migration peaks at about 80, 75, and 38 nm in Ag, Cu, and Ni, respectively. The suppression of GB migration below a critical size can be attributed to GB relaxation during sample processing or by postthermal annealing. With relaxed GBs the governing deformation mechanism of nanograins shifts from GB migration to formation of through-grain twins or stacking faults. GB relaxation, analogous to GB segregation, offers a novel approach to stabilizing nanograined materials under mechanical loading.

One-Step Laser Encapsulation of Nano-Cracking Strain Sensors

Development of flexible strain sensors that can be attached directly onto the skin, such as skin-mountable or wearable electronic devices, has recently attracted attention. However, such flexible sensors are generally exposed to various harsh environments, such as sweat, humidity, or dust, which cause noise and shorten the sensor lifetimes. This study reports the development of a nano-crack-based flexible sensor with mechanically, thermally, and chemically stable electrical characteristics in external environments using a novel one-step laser encapsulation (OLE) method optimized for thin films. The OLE process allows simultaneous patterning, cutting, and encapsulating of a device using laser cutting and thermoplastic polymers. The processes are simplified for economical and rapid production (one sensor in 8 s). Unlike other encapsulation methods, OLE does not degrade the performance of the sensor because the sensing layers remain unaffected. Sensors protected with OLE exhibit mechanical, thermal, and chemical stability under water-, heat-, dust-, and detergent-exposed conditions. Finally, a waterproof, flexible strain sensor is developed to detect motions around the eye, where oil and sweat are generated. OLE-based sensors can be used in several applications that are exposed to a large amount of foreign matter, such as humid or sweaty environments.

Size effect on the deformation mechanisms of nanocrystalline platinum thin films

This paper reports a study of time-resolved deformation process at the atomic scale of a nanocrystalline Pt thin film captured in situ under a transmission electron microscope. The main mechanism of plastic deformation was found to evolve from full dislocation activity-enabled plasticity in large grains (with grain size d > 10 nm), to partial dislocation plasticity in smaller grains (with grain size 10 nm < d < 6 nm), and grain boundary-mediated plasticity in the matrix with grain sizes d < 6 nm. The critical grain size for the transition from full dislocation activity to partial dislocation activity was estimated based on consideration of stacking fault energy. For grain boundary-mediated plasticity, the possible contributions to strain rate of grain creep, grain sliding and grain rotation to plastic deformation were estimated using established models. The contribution of grain creep is found to be negligible, the contribution of grain rotation is effective but limited in magnitude, and grain sliding is suggested to be the dominant deformation mechanism in nanocrystalline Pt thin films. This study provided the direct evidence of these deformation processes at the atomic scale.

Large strain synergetic material deformation enabled by hybrid nanolayer architectures

Nanolayered metallic composites are much stronger than pure nanocrystalline metals due to their high density of hetero-interfaces. However, they are usually mechanically instable due to the deformation incompatibility among the soft and hard constituent layers promoting shear instability. Here we designed a hybrid material with a heterogeneous multi-nanolayer architecture. It consists of alternating 10 nm and 100 nm-thick Cu/Zr bilayers which deform compatibly in both stress and strain by utilizing the layers’ intrinsic strength, strain hardening and thickness, an effect referred to as synergetic deformation. Micropillar tests show that the 6.4 GPa-hard 10 nm Cu/Zr bilayers and the 3.3 GPa 100 nm Cu layers deform in a compatible fashion up to 50% strain. Shear instabilities are entirely suppressed. Synergetic strengthening of 768 MPa (83% increase) compared to the rule of mixture is observed, reaching a total strength of 1.69 GPa. We present a model that serves as a design guideline for such synergetically deforming nano-hybrid materials.

Manipulating the interfacial structure of nanomaterials to achieve a unique combination of strength and ductility

The control of interfaces in engineered nanostructured materials has met limited success compared with that which has evolved in natural materials, where hierarchical structures with distinct interfacial states are often found. Such interface control could mitigate common limitations of engineering nanomaterials. For example, nanostructured metals exhibit extremely high strength, but this benefit comes at the expense of other important properties like ductility. Here, we report a technique for combining nanostructuring with recent advances capable of tuning interface structure, a complementary materials design strategy that allows for unprecedented property combinations. Copper-based alloys with both grain sizes in the nanometre range and distinct grain boundary structural features are created, using segregating dopants and a processing route that favours the formation of amorphous intergranular films. The mechanical behaviour of these alloys shows that the trade-off between strength and ductility typically observed for metallic materials is successfully avoided here.

Nanocrystalline metals often exhibit high strength yet suffer from poor ductility. Here, the authors employ grain boundary engineering to overcome this problem by introducing amorphous intergranular films, which enables superior mechanical properties in copper-zirconium alloys.

Designing nanomaterials with desired mechanical properties by constraining the evolution of their grain shapes

Grain shapes are acknowledged to impact nanomaterials' overall properties. Research works on this issue include grain-elongation and grain-strain measurements and their impacts on nanomaterials' mechanical properties. This paper proposes a stochastic model for grain strain undergoing severe plastic deformation. Most models deal with equivalent radii assuming that nanomaterials' grains are spherical. These models neglect true grain shapes. This paper also proposes a theoretical approach of extending existing models by considering grain shape distribution during stochastic design and modelling of nanomaterials' constituent structures and mechanical properties. This is achieved by introducing grain 'form'. Example 'forms' for 2-D and 3-D grains are proposed. From the definitions of form, strain and Hall-Petch-Relationship to Reversed-Hall-Petch-Relationship, data obtained for nanomaterials' grain size and conventional materials' properties are sufficient for analysis. Proposed extended models are solved simultaneously and tested with grain growth data. It is shown that the nature of form evolution depends on form choice and dimensional space. Long-run results reveal that grain boundary migration process causes grains to become spherical, grain rotation coalescence makes them deviate away from becoming spherical and they initially deviate away from becoming spherical before converging into spherical ones due to the TOTAL process. Percentage deviations from spherical grains depend on dimensional space and form: 0% minimum and 100% maximum deviations were observed. It is shown that the plots for grain shape functions lie above the spherical (control) value of 1 in 2-D grains for all considered grain growth mechanisms. Some plots lie above the spherical value, and others approach the spherical value before deviating below it when dealing with 3-D grains. The physical interpretations of these variations are explained from elementary principles about the different grain growth mechanisms. It is observed that materials whose grains deviate further away from the spherical ones have more enhanced properties, while materials with spherical grains have lesser properties. It is observed that there exist critical states beyond which Hall-Petch Relationship changes to Reversed Hall-Petch Relationship. It can be concluded that if grain shapes in nanomaterials are constrained in the way they evolve, then nanomaterials with desired properties can be designed.

Grain Size Distribution Effect on Mechanical Behavior of Nanocrystalline Materials

Grain size distribution effect on the mechanical behavior of NiTi and Vitroperm alloys were investigated. Yielding at significantly lower stresses than found in equiaxed counterparts, along with well defined strain hardening was observed in these nanocrystalline materials with large grains embedded in the matrix during tensile deformation at temperatures of 0.4Tm. At higher temperature the effect of grain size distribution on yield stress was not revealed while plasticity was increased in 50% in NiTi alloy with bimodal grain size structure.

Experiment and FEM Analysis of Tensile Behavior of Bimodal Nanocrystalline Al-Mg Alloys

The tensile behavior of bimodal nanocrystalline Al-7.5Mg alloys was investigated using experiments and two-dimensional axisymmetric elastic-plastic finite element method (FEM). Cryomilled nanocrystalline powders blended with 15% and 30% unmilled coarse-grained powders were consolidated by hot isostatic pressing followed by extrusion to produce bulk bimodal nanocrystalline Al-7.5Mg alloys, which were comprised of nanocrystalline grains separated by coarse-grain regions. The calculated stress-strain curves have acceptable agreement with experimental curves of the bimodal structures. The bimodal Al-7.5Mg alloys show reasonable ductility while retaining enhanced strength compared to conventional alloys and nanocrystalline metals.

Plasticity in Nanocrystalline and Amorphous Metals: Similarities at the Atomic Scale

For metallic alloys, the amorphous state is often regarded as the limiting structure as grain size is reduced towards zero. One interesting consequence of this limit is that the properties of the finest nanocrystalline metals must begin to resemble those of metallic glasses. In this work we focus upon the nature of the plastic yield mechanisms in these material classes, and seek to identify commonalities and disparities in the nature of plastic yield in glasses and nanocrystals. The discussion is presented with reference to static atomistic simulations of (i) an amorphous binary alloy, and (ii) a nanocrystalline Ni specimen with grain size of 3 nm. We show that both these materials deform by the operation of fine atomic shearing events, and both exhibit asymmetric yielding as a consequence.

In situ observation of dislocation behavior in nanometer grains

Using a newly developed nanoscale deformation device, atomic scale and time-resolved dislocation dynamics have been captured in situ under a transmission electron microscope during the deformation of a Pt ultrathin film with truly nanometer grains (diameter d< ~ 10 nm). We demonstrate that dislocations are highly active even in such tiny grains. For the larger grains (d ~ 10 nm), full dislocations dominate and their evolution sometimes leads to the formation, destruction, and reformation of Lomer locks. In smaller grains, partial dislocations generating stacking faults are prevalent.

The effects of substitution of Cr for Mo on the mechanical properties of nanocrystalline Mo5Si3 films

A series of nanocrystalline (Mo(x)Cr(1-x))(5)Si(3) films with an average grain size of 8 nm has been prepared on Ti-6A1-4V alloy substrates by glow discharge. The effect of substitution of Cr for Mo on the hardness, elastic modulus and plastic deformability of the nanocrystalline (Mo(x)Cr(1-x))(5)Si(3) film was investigated using the nanoindentation method. The results reveal that the hardness of nanocrystalline (Mo(x)Cr(1-x))(5)Si(3) films slightly decreases with increasing Cr content. In contrast, the plastic deformability significantly increases with increasing Cr content.

Plastic Deformation Recovery in Freestanding Nanocrystalline Aluminum and Gold Thin Films

In nanocrystalline metals, lack of intragranular dislocation sources leads to plastic deformation mechanisms that substantially differ from those in coarse-grained metals. However, irrespective of grain size, plastic deformation is considered irrecoverable. We show experimentally that plastically deformed nanocrystalline aluminum and gold films with grain sizes of 65 nanometers and 50 nanometers, respectively, recovered a substantial fraction (50 to 100%) of plastic strain after unloading. This recovery was time dependent and was expedited at higher temperatures. Furthermore, the stress-strain characteristics during the next loading remained almost unchanged when strain recovery was complete. These observations in two dissimilar face-centered cubic metals suggest that strain recovery might be characteristic of other metals with similar grain sizes and crystalline packing.

Grain boundary-mediated plasticity in nanocrystalline nickel

The plastic behavior of crystalline materials is mainly controlled by the nucleation and motion of lattice dislocations. We report in situ dynamic transmission electron microscope observations of nanocrystalline nickel films with an average grain size of about 10 nanometers, which show that grain boundary-mediated processes have become a prominent deformation mode. Additionally, trapped lattice dislocations are observed in individual grains following deformation. This change in the deformation mode arises from the grain size-dependent competition between the deformation controlled by nucleation and motion of dislocations and the deformation controlled by diffusion-assisted grain boundary processes.

Deformation mechanisms in free-standing nanoscale thin films: a quantitative in situ transmission electron microscope study

We have added force and displacement measurement capabilities in the transmission electron microscope (TEM) for in situ quantitative tensile experimentation on nanoscale specimens. Employing the technique, we measured the stress-strain response of several nanoscale free-standing aluminum and gold films subjected to several loading and unloading cycles. We observed low elastic modulus, nonlinear elasticity, lack of work hardening, and macroscopically brittle nature in these metals when their average grain size is 50 nm or less. Direct in situ TEM observation of the absence of dislocations in these films even at high stresses points to a grain-boundary-based mechanism as a dominant contributing factor in nanoscale metal deformation. When grain size is larger, the same metals regain their macroscopic behavior. Addition of quantitative capability makes the TEM a versatile tool for new fundamental investigations on materials and structures at the nanoscale.

Plastic Deformation with Reversible Peak Broadening in Nanocrystalline Nickel

Plastic deformation in coarse-grained metals is governed by dislocation-mediated processes. These processes lead to the accumulation of a residual dislocation network, producing inhomogeneous strain and an irreversible broadening of the Bragg peaks in x-ray diffraction. We show that during plastic deformation of electrodeposited nanocrystalline nickel, the peak broadening is reversible upon unloading; hence, the deformation process does not build up a residual dislocation network. The results were obtained during in situ peak profile analysis using the Swiss Light Source. This in situ technique, based on well-known peak profile analysis methods, can be used to address the relationship between microstructure and mechanical properties in nanostructured materials.

High tensile ductility in a nanostructured metal

Nanocrystalline metals--with grain sizes of less than 100 nm--have strengths exceeding those of coarse-grained and even alloyed metals, and are thus expected to have many applications. For example, pure nanocrystalline Cu (refs 1-7) has a yield strength in excess of 400 MPa, which is six times higher than that of coarse-grained Cu. But nanocrystalline materials often exhibit low tensile ductility at room temperature, which limits their practical utility. The elongation to failure is typically less than a few per cent; the regime of uniform deformation is even smaller. Here we describe a thermomechanical treatment of Cu that results in a bimodal grain size distribution, with micrometre-sized grains embedded inside a matrix of nanocrystalline and ultrafine (<300 nm) grains. The matrix grains impart high strength, as expected from an extrapolation of the Hall-Petch relationship. Meanwhile, the inhomogeneous microstructure induces strain hardening mechanisms that stabilize the tensile deformation, leading to a high tensile ductility--65% elongation to failure, and 30% uniform elongation. We expect that these results will have implications in the development of tough nanostructured metals for forming operations and high-performance structural applications including microelectromechanical and biomedical systems.