This review examines the size effects observed in the mechanical strength of thin metal films and small samples such as single-crystalline pillars, whiskers, and wires. Experimental results from mechanical testing and electron microscopy studies, as well as recent insights from discrete dislocation dynamics simulations, are presented. The size dependency of deformation may be separated into three regimes: the nanometer regime of roughly 100 nm and below, an intermediate regime between 100 nm and approximately 1 μm, and a bulk-like regime. We argue that there is no scaling law with one universal power-law exponent encompassing the entire range. Instead, there are a number of different mechanisms and underlying effects, e.g., the initial dislocation microstructure or loading conditions. The complex interaction of these mechanisms leads to the typically observed scaling behavior.

Microcompression tests were performed on focused-ion-beam-machined micropillars of several body-centered-cubic metals (W, Mo, Ta, and Nb) at room temperature. The relationship between yield strength and pillar diameter as well as the deformation morphologies were found to correlate with a parameter specific for bcc metals, i.e., the critical temperature T(c). This finding sheds new light on the phenomenon of small-scale plasticity in largely unexplored non-fcc metals.

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Plastic deformation of micron and sub-micron scale specimens is characterized by intermittent sequences of large strain bursts (dislocation avalanches) which are separated by regions of near-elastic loading. In the present investigation we perform a statistical characterization of strain bursts observed in stress-controlled compressive deformation of monocrystalline Molybdenum micropillars. We characterize the bursts in terms of the associated elongation increments and peak deformation rates, and demonstrate that these quantities follow power-law distributions that do not depend on specimen orientation or stress rate. We also investigate the statistics of stress increments in between the bursts, which are found to be Weibull distributed and exhibit a characteristic size effect. We discuss our findings in view of observations of deformation bursts in other materials, such as face-centered cubic and hexagonal metals.

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