We have calculated the phonon spectra of aluminum as a function of strain using density functional perturbation theory for <110>, <100>, and <111> uniaxial tension, as well as relaxed <112>[111] shear. In all four cases, phonon instabilities occur at points away from the center of the Brillouin zone and intrude before the material becomes unstable according to elastic stability criteria. This is the first time the ideal strength of a metal has been shown to be dictated by instabilities in the acoustic phonon spectra. We go on to describe the crystallography of the unstable modes, all of which are shear in character. This work further suggests that shear failure is an inherent property of aluminum even in an initially dislocation-free perfect crystal.
The ideal strength is the minimum stress required to plastically deform an infinite defectfree crystal and is an upper bound to the strength of a real crystal. Disturbingly, however, the best available experimental estimates of the ideal strengths of tungsten and molybdenum are 25-50% above the values predicted by recent ab initio density-functional calculations. This work resolves this discrepancy by extending the theoretical calculations to account for the triaxial state of stress seen in the nanoindentation experiments and by adjusting the experimental values to account for the crystallography of loading and the nonlinearity of the elastic response at large strains. Although an implicit assumption in many discussions of mechanical properties is that the ideal strength is not experimentally observable, as the true strength of most materials is limited by lattice defects, the close agreement between corrected experimental and theoretical estimates of ideal strength suggests that the ideal strength of some materials can be observed directly using nanoindentation.
The ideal structural steel combines high strength with excellent fracture toughness. In this paper we consider the limits of strength and toughness from two perspectives. The first perspective is theoretical. It has recently become possible to compute the ideal shear and tensile strengths of defect-free crystals. While the ferromagnetism of bcc Fe makes it a particularly difficult problem, we can estimate its limiting properties from those of similar materials. The expected behavior at the limit of strength contains many familiar features, including cleavage on {100}, ͗111͘ slip on multiple planes, "conditionally" brittle behavior at low temperature and a trend away from brittle behavior on alloying with Ni. The behavior of fcc materials at the limit of strength suggests that true cleavage will not happen in austenitic steels. The results predict an ideal cleavage stress near 10.5 GPa, and a shear strength near 6.5 GPa. The second perspective is practical: how to maximize the toughness of high-strength steel. Our discussion here is limited to the subtopic that has been the focus of research in our own group: the use of thermal treatments to inhibit transgranular brittle fracture in lath martensitic steels. The central purpose of the heat treatments described here is grain refinement, and the objective of grain refinement is to limit the crystallographic coherence length for transgranular crack propagation. There are two important sources of transgranular embrittlement: thermal (or, more properly, mechanical) embrittlement at the ductile-brittle transition, and hydrogen embrittlement from improper heat treatment or environmental attack. As we shall discuss, these embrittling mechanisms use different crack paths in lath martensitic steels and, therefore, call for somewhat different remedies.
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