Nuclear-grade graphite is a critically important high-temperature structural material for current and potentially next generation of fission reactors worldwide. It is imperative to understand its damage-tolerant behaviour and to discern the mechanisms of damage evolution under in-service conditions. Here we perform in situ mechanical testing with synchrotron X-ray computed micro-tomography at temperatures between ambient and 1,000 °C on a nuclear-grade Gilsocarbon graphite. We find that both the strength and fracture toughness of this graphite are improved at elevated temperature. Whereas this behaviour is consistent with observations of the closure of microcracks formed parallel to the covalent-sp²-bonded graphene layers at higher temperatures, which accommodate the more than tenfold larger thermal expansion perpendicular to these layers, we attribute the elevation in strength and toughness primarily to changes in the residual stress state at 800-1,000 °C, specifically to the reduction in significant levels of residual tensile stresses in the graphite that are 'frozen-in' following processing.

Tear resistance is of vital importance in the various functions of skin, especially protection from predatorial attack. Here, we mechanistically quantify the extreme tear resistance of skin and identify the underlying structural features, which lead to its sophisticated failure mechanisms. We explain why it is virtually impossible to propagate a tear in rabbit skin, chosen as a model material for the dermis of vertebrates. We express the deformation in terms of four mechanisms of collagen fibril activity in skin under tensile loading that virtually eliminate the possibility of tearing in pre-notched samples: fibril straightening, fibril reorientation towards the tensile direction, elastic stretching and interfibrillar sliding, all of which contribute to the redistribution of the stresses at the notch tip.

Multiple-principal element alloys known as high-entropy alloys have rapidly been gaining attention for the vast variety of compositions and potential combinations of properties that remain to be explored. Of these alloys, one of the earliest, the ‘Cantor alloy’ CrMnFeCoNi, displays excellent damage-tolerance with tensile strengths of ∼1 GPa and fracture toughness values in excess of 200 MPa√m; moreover, these mechanical properties tend to further improve at cryogenic temperatures. However, few studies have explored its corresponding fatigue properties. Here we expand on our previous study to examine the mechanics and mechanisms of fatigue-crack propagation in the CrMnFeCoNi alloy (∼7 μm grain size), with emphasis on long-life, near-threshold fatigue behavior, specifically as a function of load ratio at temperatures between ambient and liquid-nitrogen temperatures (293 K–77 K). We find that ΔKth fatigue thresholds are decreased with increasing positive load ratios, R between 0.1 and 0.7, but are increased at decreasing temperature. These effects can be attributed to the role of roughness-induced crack closure, which was estimated using compliance measurements. Evidence of deformation twinning at the crack tip during fatigue-crack advance was not apparent at ambient temperatures but seen at higher stress intensities (ΔK ∼ 20 MPa√m) at 77 K by post mortem microstructural analysis for tests at R = 0.1 and particularly at 0.7. Overall, the fatigue behavior of this alloy was found to be superior, or at least comparable, to conventional cryogenic and TWIP steels such as 304 L or 316 L steels and Fe-Mn steels; these results coupled with the remarkable strength and fracture toughness of the Cantor alloy at low temperatures indicate significant promise for the utility of this material for applications at cryogenic environments.

Bulk-metallic glasses (BMGs) are now candidate materials for structural applications due to their exceptional strength and toughness. However, their fatigue resistance can be poor and inconsistent, severely limiting their potential as reliable structural materials. As fatigue limits are invariably governed by the local arrest of microscopically small cracks at microstructural features, the lack of microstructure in monolithic glasses, often coupled with other factors, such as the ease of crack formation in shear bands or a high susceptibility to corrosion, can lead to low fatigue limits (some ~1/20 of their tensile strengths) and highly variable fatigue lives. BMG-matrix composites can provide a solution here as their duplex microstructures can arrest shear bands at a second phase to prevent cracks from exceeding critical size; under these conditions, fatigue limits become comparable with those of crystalline alloys. Here, we report on a Pd-based glass that similarly has high fatigue resistance but without a second phase. This monolithic glass displays high intrinsic toughness from extensive shear-band proliferation with cavitation and cracking effectively obstructed. We find that this property can further promote fatigue resistance through extrinsic crack-tip shielding, a mechanism well known in crystalline metals but not previously reported in BMGs, whereby cyclically loaded cracks propagate in a highly "zig-zag" manner, creating a rough "staircase-like" profile. The resulting crack-surface contact (roughness-induced crack closure) elevates fatigue properties to those comparable to crystalline alloys, and the accompanying plasticity helps to reduce flaw sensitivity in the glass, thereby promoting structural reliability.

High-entropy alloys are an intriguing new class of metallic materials that derive their properties from being multi-element systems that can crystallize as a single phase, despite containing high concentrations of five or more elements with different crystal structures. Here we examine an equiatomic medium-entropy alloy containing only three elements, CrCoNi, as a single-phase face-centred cubic solid solution, which displays strength-toughness properties that exceed those of all high-entropy alloys and most multi-phase alloys. At room temperature, the alloy shows tensile strengths of almost 1 GPa, failure strains of ∼70% and KJIc fracture-toughness values above 200 MPa  m(1/2); at cryogenic temperatures strength, ductility and toughness of the CrCoNi alloy improve to strength levels above 1.3 GPa, failure strains up to 90% and KJIc values of 275 MPa  m(1/2). Such properties appear to result from continuous steady strain hardening, which acts to suppress plastic instability, resulting from pronounced dislocation activity and deformation-induced nano-twinning.

Nacre’s structure-property relationships have been a source of inspiration for designing advanced functional materials with both high strength and toughness. These outstanding mechanical properties have been mostly attributed to the interplay between aragonite platelets and organic matrices in the typical brick-and-mortar structure. Here, we show that crystallographically co-oriented stacks of aragonite platelets, in both columnar and sheet nacre, define another hierarchical level that contributes to the toughening of nacre. By correlating piezo-Raman and micro-indentation results, we quantify the residual strain energy associated with strain hardening capacity. Our findings suggest that the aragonite stacks, with characteristic dimensions of around 20 µm, effectively store energy through cooperative plastic deformation. The existence of a larger length scale beyond the brick-and-mortar structure offers an opportunity for a more efficient implementation of biomimetic design.

Temperature is known to affect deformation mechanisms in metallic alloys. As temperature decreases, the stacking-fault energy in many face-centered cubic (fcc) alloys decreases, resulting in a change of deformation mode from dislocation slip to deformation twinning. Such an impact of temperature can be more complex in compositionally heterogeneous microstructures that exhibit, for example, local concentration fluctuation such as that in multi-principal element alloys. In this work, we compare the dislocation behavior and mechanical properties of a fcc Cr20Mn10Fe30Co30Ni10 high-entropy alloy at ambient and liquid-nitrogen temperatures. We find that a network of stacking faults is formed by uniformly extended dislocations at ambient temperatures with low stacking-fault energy, whereas at lower temperatures, uneven dissociation of dislocations becomes significant, which results in severe dislocation pile-ups together with their pronounced entanglement. Our findings indicate that as the stacking-fault energy decreases with decreasing temperature, the heterogeneity of the distribution of elements becomes more dominant in tuning the local variation of lattice resistance. As a result, the change in dislocation behavior at low temperatures strongly affects microstructural evolution and consequently leads to significantly more pronounced work hardening.

Strategies involving metastable phases have been the basis of the design of numerous alloys, yet research on metastable high-entropy alloys is still in its infancy. In dual-phase high-entropy alloys, the combination of local chemical environments and loading-induced crystal structure changes suggests a relationship between deformation mechanisms and chemical atomic distribution, which we examine in here in a Cantor-like Cr₂₀Mn₆Fe₃₄Co₃₄Ni₆ alloy, comprising both face-centered cubic (fcc) and hexagonal closed packed (hcp) phases. We observe that partial dislocation activities result in stable three-dimensional stacking-fault networks. Additionally, the fraction of the stronger hcp phase progressively increases during plastic deformation by forming at the stacking-fault network boundaries in the fcc phase, serving as the major source of strain hardening. In this context, variations in local chemical composition promote a high density of Lomer-Cottrell locks, which facilitate the construction of the stacking-fault networks to provide nucleation sites for the hcp phase transformation.

Damage tolerance can be an elusive characteristic of structural materials requiring both high strength and ductility, properties that are often mutually exclusive. High-entropy alloys are of interest in this regard. Specifically, the single-phase CrMnFeCoNi alloy displays tensile strength levels of ∼ 1 GPa, excellent ductility (∼ 60-70%) and exceptional fracture toughness (KJIc>200 MPa√m). Here through the use of in situ straining in an aberration-corrected transmission electron microscope, we report on the salient atomistic to micro-scale mechanisms underlying the origin of these properties. We identify a synergy of multiple deformation mechanisms, rarely achieved in metallic alloys, which generates high strength, work hardening and ductility, including the easy motion of Shockley partials, their interactions to form stacking-fault parallelepipeds, and arrest at planar slip bands of undissociated dislocations. We further show that crack propagation is impeded by twinned, nanoscale bridges that form between the near-tip crack faces and delay fracture by shielding the crack tip.

Bisphosphonates are the most widely prescribed pharmacologic treatment for osteoporosis and reduce fracture risk in postmenopausal women by up to 50%. However, in the past decade these drugs have been associated with atypical femoral fractures (AFFs), rare fractures with a transverse, brittle morphology. The unusual fracture morphology suggests that bisphosphonate treatment may impair toughening mechanisms in cortical bone. The objective of this study was to compare the compositional and mechanical properties of bone biopsies from bisphosphonate-treated patients with AFFs to those from patients with typical osteoporotic fractures with and without bisphosphonate treatment. Biopsies of proximal femoral cortical bone adjacent to the fracture site were obtained from postmenopausal women during fracture repair surgery (fracture groups, n = 33) or total hip arthroplasty (nonfracture groups, n = 17). Patients were allocated to five groups based on fracture morphology and history of bisphosphonate treatment [+BIS Atypical: n = 12, BIS duration: 8.2 (3.0) y; +BIS Typical: n = 10, 7.7 (5.0) y; +BIS Nonfx: n = 5, 6.4 (3.5) y; -BIS Typical: n = 11; -BIS Nonfx: n = 12]. Vibrational spectroscopy and nanoindentation showed that tissue from bisphosphonate-treated women with atypical fractures was harder and more mineralized than that from bisphosphonate-treated women with typical osteoporotic fractures. In addition, fracture mechanics measurements showed that tissue from patients treated with bisphosphonates had deficits in fracture toughness, with lower crack-initiation toughness and less crack deflection at osteonal boundaries than that of bisphosphonate-naïve patients. Together, these results suggest a deficit in intrinsic and extrinsic toughening mechanisms, which contribute to AFFs in patients treated with long-term bisphosphonates.