Plasticity and fracture of materials at the nanoscale levels can deviate significantly from the same phenomena in bulk properties, which may have important implications if they are to be used in real-world engineering systems. Nanoscale metal–metal multilayered materials provide a model material system platform to understand plasticity and fracture based on dislocation interactions with microstructural features. Recently, there is a growing trend to understand the fracture of multilayered materials to see the interactions between the crack and multilayered interface through novel experimentation techniques. In this review, we will introduce the rationale, the current microfracture methods to test and analyze the multilayer fracture behavior and the challenges faced in performing them. Four examples of in situ fracture techniques are highlighted in this work through tensile testing of film on a substrate: microfracture clamped beam bending technique across the multilayers and delamination along the multilayered interface.

Nanostructured multiphase metallic materials present extraordinary properties, such as high strength, enhanced fatigue and radiation resistance, and thermal stability, compared to conventional bulk metallic materials. Previous research studies have shown that their deformation and fracture behavior are dominated by defect interactions at internal interfaces. In situ straining, including nanoindentation, compression, and tension, in a transmission electron microscope (TEM) has emerged as a powerful tool to investigate the physics of defect–interface interactions at the nano-scale and even atomic scale. The mechanistic insights gained from these experiments coupled with dislocation theory and atomistic modeling has helped develop a fundamental understanding of the mechanical properties. In this article, through some recent investigations on observing dislocation and interface activities, crack propagation, and nanopillar compression, we present current progress in utilizing in situ TEM straining to examine interface-dominated deformation mechanisms.

Fatigue performance of metallic nanolayered composites (NLCs) has been gaining more and more attention due to the rapid development in the field of both micro-electro-mechanical systems and high-performance engineering structure materials and the increasing demand for long-term fatigue reliability. Metallic NLCs have exhibited different damage behaviors due to the effect of high-density heterogeneous interface compared with bulk materials and thin metal films. In this review paper, the cyclic deformation damage behavior, fatigue cracking feature, and fatigue properties of some metallic NLCs are reviewed. Effects of length scales, including layer thickness and grain size, on fatigue damage behaviors of the NLCs are revealed, and the transition of the fatigue cracking behavior and the corresponding damage mechanism are discussed. Then, the fatigue properties of some typical metallic NLCs are presented and compared with that of bulk materials and metal thin films. The effect of interface type and grain boundary alignment is also discussed to correlate with fatigue cracking resistance of the NLCs. Finally, some prospective research topics on fatigue performance of metallic NLCs are addressed.

Ceramics are strong but brittle. According to the classical theories, ceramics are brittle mainly because dislocations are suppressed by cracks. Here, the authors report the combined elastic and plastic deformation measurements of nanoceramics, in which dislocation-mediated stiff and ductile behaviors were detected at room temperature. In the synchrotron-based deformation experiments, a marked slope change is observed in the stress–strain relationship of MgAl2O4 nanoceramics at high pressures, indicating that a deformation mechanism shift occurs in the compression and that the nanoceramics sample is elastically stiffer than its bulk counterpart. The bulk-sized MgAl2O4 shows no texturing at pressures up to 37 GPa, which is compatible with the brittle behaviors of ceramics. Surprisingly, substantial texturing is seen in nanoceramic MgAl2O4 at pressures above 4 GPa. The observed stiffening and texturing indicate that dislocation-mediated mechanisms, usually suppressed in bulk-sized ceramics at low temperature, become operative in nanoceramics. This makes nanoceramics stiff and ductile.

Recent molecular dynamics simulations revealed that 〈c + a〉 dislocations in Mg were prone to dissociation on the basal plane, thus becoming sessile. Basal dissociation of 〈c + a〉 dislocations is significant because it is a major factor in the limited ductility and high work-hardening in Mg. We report an in situ transmission electron microscopy study of the deformation process using an H-bar-shaped thin foil of Mg single crystal designed to facilitate 〈c + a〉 slip, observe 〈c + a〉 dislocation activity, and establish the validity of the largely immobile 〈c + a〉 dislocations caused by the predicted basal dissociation. In addition, through detailed observations on the fine movement of some 〈c + a〉 dislocations, it was revealed that limited bowing out movement for some non-basal portions of 〈c + a〉 dislocations was possible; under certain circumstances, i.e., through attraction and reaction between two 〈c + a〉 dislocations on the same pyramidal plane, at least portions of the sessile configuration were observed to be reversed into a glissile one.

Lattice structures, defect structures, and deformation mechanisms of high-entropy alloys (HEAs) have been studied using atomistic simulations to explain their remarkable mechanical properties. These atomistic simulation techniques, such as first-principles calculations and molecular dynamics allow atomistic-level resolution of structure, defect configuration, and energetics. Following the structure–property paradigm, such understandings can be useful for guiding the design of high-performance HEAs. Although there have been a number of atomistic studies on HEAs, there is no comprehensive review on the state-of-the-art techniques and results of atomistic simulations of HEAs. This article is intended to fill the gap, providing an overview of the state-of-the-art atomistic simulations on HEAs. In particular, we discuss how atomistic simulations can elucidate the nanoscale mechanisms of plasticity underlying the outstanding properties of HEAs, and further present a list of interesting problems for forthcoming atomistic simulations of HEAs.

In this work, molecular dynamics simulations to explore the crack propagation and fracture behavior of Cu/Nb metallic nanolayered composites (MNCs) were performed. The results of this study are consistent with the previous experimental results, which illustrated that cracks in Cu and Nb layers may exhibit different propagation paths and distances under the isostrain loading condition. The analysis reveals that the interface can increase the fracture resistance of the Nb layer in Cu/Nb MNCs by providing the dislocation sources to generate the plastic strain at the front of the crack. Increasing the layer thickness can enhance the fracture resistance of both Cu and Nb layers, as the critical stress for activating the dislocation motion decreases with the increment of the layer thickness. In addition, grain boundaries (GBs) in polycrystalline Cu/Nb samples would decrease the fracture resistance of Nb layer by promoting the crack propagate along the GBs, i.e., intergranular fracture, while the effect of interface and layer thickness on the fracture resistance of MNCs will not be altered by introducing the GBs in MNCs.

In our previous study, we observed a lack of $\left\{ {10\bar{1}2} \right\}$ twinning in a deformed Mg–Y alloy, which contributed to the observed yield “symmetry.” However, the effects of texture and grain size on polycrystalline deformation made it difficult to fully understand why twinning was not active. Therefore, we report herein in-depth study by in situ transmission electron microscopy, i.e., in situ TEM. The in situ deformation of nano-sized Mg–Y pillars revealed that prismatic slip was favored over twinning, namely, the critical stress required to activate prismatic slip was lower than that for twinning. This finding diametrically differs from that reported in other nano/micro-pillar deformation studies, where twinning is always the dominant deformation mechanism. By measuring the critical stresses for basal, prismatic, and pyramidal slip systems, this in situ TEM study also sheds light on the effects of the alloying element Y on reducing the intrinsic plastic anisotropy in the Mg matrix.

Nanodomained heterogenous structures characterized by randomly dispersed nanograins (NGs) embedded in the coarser grains (CGs) have demonstrated an exciting potential to break the strength–ductility trade-off, providing high strength without the loss of ductility. Here, using a combination of discrete crystal plasticity finite element (discrete-CPFE) model and dislocation density-based CPFE model, we study the effects of grain size, volume fraction of nanograins on the strength and deformation in nanodomained materials. Our analysis shows that the overall flow stresses of nanodomained samples are equal or higher than the strengths predicted by rule of mixtures. Smaller NGs or higher volume fraction of NGs can make the nanodomained samples stronger, as they can be more effective to promote the dislocation accumulations inside the CGs and eventually raise the critical resolved shear stress for each slip system during the plastic flow. Areas surrounding NGs stored higher dislocation densities and less plastic strain, due to the restricted dislocation motion. Furthermore, NGs grain embedded in the CGs can effectively reduce the anisotropy of strength in the nanodomained samples.

Interfaces can influence the mechanical properties of metallic multilayers, even between different combinations of face-centered cubic (FCC)/body-centered cubic (BCC) constituents, as reported from many experiments. Recent literature has shown promise for fracture being delayed or even stopped at these interfaces. However, no studies have investigated the influence of their constituents on the subsequent mechanisms of fracture leading to failure. We performed in situ microfracture bending tests of the notched clamped beams made from physical vapor deposited Cu/Nb and Al/Nb multilayers. A catastrophic, linear elastic, brittle fracture was observed for the Cu/Nb beams, whereas a more delayed fracture with a gradual crack propagation was observed for the Al/Nb beams. These observations reveal differences in mechanisms because of the FCC element, interface/boundary blocking of dislocation motion, and effect of grain boundaries in the multilayers. Through this study, FCC/BCC metallic multilayers can be designed with enhanced fracture resistance and mechanical strength.

Microscale testing has enjoyed significant developments, with the majority of testing focused on tensile/compression type tests and little focus on shear testing. With the recent advances in macroscale shear testing, we developed a novel shear structure for evaluating shear properties of bulk materials and films at the microscale. The shear response in single-crystal copper oriented along the [111] direction was found to have a yield strength of ∼180 MPa. Nanocrystalline copper specimens with different orientations showed sensitivity to the film texture with a shear yield strength nearly three times that of single-crystal copper. Shear specimens were fabricated with Cu film–Si substrate interface near the middle of the shear region and compressed to fracture. The shear response showed a mixed behavior of the stiff Si substrate and softer nanocrystalline film and failed in a brittle manner, indicating a response unique to the interface.

Post-irradiation plastic strain spreading in ferritic grains is investigated by means of three-dimensional dislocation dynamics simulations, whereby dislocation-mediated plasticity mechanisms are analyzed in the presence of various disperse defect populations, for different grain size and orientation cases. Each simulated irradiation condition is then characterized by a specific “defect-induced apparent straining temperature shift” (ΔDIAT) magnitude, reflecting the statistical evolutions of dislocation mobility. It is found that the calculated ΔDIAT level closely matches the ductile-to-brittle transition temperature shift (ΔDBTT) associated with a given defect dispersion, characterized by the (average) defect size D and defect number density N. The noted ΔDIAT/ΔDBTT correlation can be explained based on plastic strain spreading arguments and applicable to many different ferritic alloy compositions, at least within the range of simulation conditions examined herein. This systematic study represents one essential step toward the development of a fully predictive, dose-dependent fracture model, adapted to polycrystalline ferritic materials.

Serrated flow is one important characteristic of shear bands through which metallic glasses (MGs) accommodate plastic deformation. Serrated flow can be affected by intrinsic properties such as elastic modulus or extrinsic variables such as strain rate. However, the influences of pre-deformation and interfaces on serrated flow are less well understood. In this study, by using in situ micropillar compression inside a scanning electron microscope, we show that pre-deformation (consisting of cyclic loading/unloading below the nominal elastic limit) suppresses serrated flows in amorphous-CuNb but enhances serrated flows in amorphous-CuZr at both high and low strain rates. Moreover, layer interfaces in Cu/amorphous-CuNb multilayers mitigate serrated flows, and the average stress drop and strain duration associated with shear banding process can be tailored. Strain accommodation and energy dissipation via shear banding have clear impact on serrated flows. This study provides new perspectives on tailoring serrated flows and enhancing plastic deformation of MGs.

Employing atomic-scale simulations, the response of a high-angle grain boundary (GB), the soft/hard GB, against external loading was systematically investigated. Under tensile loading close to the hard orientation, strain-induced dynamic recrystallization was observed to initiate through direct soft-to-hard grain reorientation, which was triggered by stress mismatch, inhibited by surface tension from the soft-hard GB, and proceeded by interface ledges. Such grain reorientation corresponds with expansion and contraction of the hard grain along and perpendicular to the loading direction, respectively, accompanied by local atomic shuffling, providing relatively large normal strain of 8.3% with activation energy of 0.04 eV per atom. Tensile strain and residual dislocations on the hard/soft GB facilitate the initiation of dynamic recrystallization by lowering the energy barrier and the critical stress for grain reorientation, respectively.

Silicon is a promising material for lithium-ion batteries. However, it expands by 300% on lithiation, leading to fracture. Nanostructuring of silicon is expected to be a promising method to improve the mechanical strength of the silicon electrodes. In the present work, a unique battery test cell was designed and fabricated to study the in situ stress evolution in the silicon nanowire (SiNW) electrode during electrochemical lithiation using synchrotron X-ray microdiffraction. The stress in the SiNWs at pristine state and during lithiation was evaluated using energy scans. The average stress in the pristine nanowires was found to be ∼40 MPa tensile, which changed to ∼325 MPa compressive on lithiation. Further, the deviatoric stress state in the SiNWs during lithiation was evaluated using Laue diffraction and the lithiated nanowires were found to be in triaxial stress state with high shear stresses. The technique and the findings provide new and more in-depth understanding of the stress evolution in the SiNWs during electrochemical lithiation.