1. CHAPTER 7: DISLOCATIONS AND STRENGTHENING
In Ch.6
Plastic (permanent) & Elastic (reversible)
Yield Strength and hardness are a measure of materials resistance to deformation
In microscopic scale what is going on ?
Net movement of large number of atoms in response to an applied stress
Involves movement of dislocations, in Ch. 4
How does strengthening happen ?
Why do some materials are stronger than others ?
How can one manipulate dislocations and their motion ?

2. Dislocations & Materials Classes
• Metals: Disl. motion easier.
-non-directional bonding
-close-packed directions
for slip.
electron cloud
ion cores +
• Covalent Ceramics
(Si, diamond): Motion hard.
-directional (angular) bonding
• Ionic Ceramics (NaCl):
Motion hard.
-need to avoid ++ and - -
neighbors. + -

3. Dislocation Motion Dislocations & plastic deformation
Cubic & hexagonal metals - plastic deformation by plastic shear or slip where one plane of atoms slides over adjacent plane by defect motion (dislocations).
So we saw that above the yield stress plastic deformation occurs. But how? In a perfect single crystal for this to occur every bond connecting tow planes would have to break at once! Large energy requirement
Now rather than entire plane of bonds needing to be broken at once, only the bonds along dislocation line are broken at once.
If dislocations don't move, deformation doesn't occur!
Adapted from Fig. 7.1, Callister 7e.

4. DISLOCATION MOTION How do we generate the dislocation motion ?
Plastically
stretched
zinc
single
crystal.
• Produces plastic deformation !
• Bonds are incrementally broken and re-formed. Much less force is needed , why ?
Adapted from Fig. 7.9, Callister 6e. (Fig. 7.9 is from C.F. Elam, The Distortion of Metal Crystals, Oxford University Press, London, 1935.)
SLIP PLANE
Adapted from Fig. 7.1, Callister 6e. (Fig. 7.1 is adapted from A.G. Guy, Essentials of Materials Science, McGraw-Hill Book Company,
New York, p. 153.)
SEE THE MOVIE AGAIN !
Adapted from Fig. 7.8, Callister 6e.
• If dislocations don't move,
plastic deformation doesn't happen!
How do we generate the dislocation motion ? 3

5. DISLOCATION MOTION deformed apply force Initial state O1 O0 t3 t2 t1
The motion of a single dislocation across the plane causes
the top half of the crystal to move (to slip) with respect to
the bottom half but we can not have to break all the bonds
across the middle plane simultaneously (which would
require a very large force).
The slip plane (O0-O1)– the crystallographic plane of dislocation
motion.

6. STRESS and Dislocation Motion
Dislocation line
NOT be parallel to the dislocation line !

7. Dislocation Motion
Dislocation moves along slip plane in slip direction perpendicular to dislocation line
Slip direction same direction as Burgers vector
Edge dislocation
Adapted from Fig. 7.2, Callister 7e.
Screw dislocation

8. STRESS AND DISLOCATION MOTION

9. STRESS field around dislocations
Bonds are Compressed
Bonds are Stretched
WHY is there a stress field ?
Atoms try to relax by trying to achieve their positions for the case if there was not a dislocation in the vicinity !

10. Stress fields of dislocations interacting !
The strain fields around dislocations interact with each other. Hence, they exert force on each other.
Edge dislocations, when they are in the same plane, they repel each other if they have the same
sign (direction of the Burgers vector). WHY ?
They can attract and annihilate if they have opposite signs. PROVE !

11. Dislocation Density
The number of dislocations in a material is expressed using the term dislocation density - the total dislocation length per unit volume or the # of dislocations intersecting a unit area. Units are mm / mm3, or just / mm
Dislocation densities can vary from 103 mm-2 in carefully solidified metal crystals to 1010 mm-2 in heavily deformed metals.
Where do Dislocations come from, what are their sources ?
Most crystalline materials, especially metals, have dislocations in their as-formed state, mainly as a result of stresses (mechanical, thermal...) associated with the manufacturing processes used.
The number of dislocations increases dramatically during plastic deformation.
Dislocations spawn from existing dislocations, grain boundaries and surfaces and other “defects” .
NICE SIMULATIONS =>

12. Deformation Mechanisms
Slip System
Slip plane - plane allowing easiest slippage
Wide interplanar spacings - highest planar densities
Slip direction - direction of movement - Highest linear densities
FCC Slip occurs on {111} planes (close-packed) in <110> directions (close-packed)
=> total of 12 slip systems in FCC
in BCC & HCP other slip systems occur
Adapted from Fig. 7.6, Callister 7e.

13. SLIP SYSTEMS !!!
Dislocations move with ease on certain crystallographic planes and along certain directions on these planes !
The plane is called a slip plane
The direction is called a slip direction
Combination of the plane of slip and direction is a slip system
The slip planes and directions are those of highest packing density.
The distance between atoms is shorter than the average…High number of coordination along the planes also important !
PLS SEE TABLE 7.1 in ur books , page 180 !!!

14. Concept Check
Page 181, in 7th edition !

15. Stress and Dislocation Motion
• Crystals slip due to a resolved shear stress, tR.
• Applied tension can produce such a stress.
Applied tensile
stress:
= F/A s
direction
slip F A
slip plane
normal, ns
Resolved shear
stress: tR = F s /A
direction
slip AS FS
direction
slip
Relation between s
and tR = FS
/AS F
cos l A / f nS AS
l+f  90

16. Critical Resolved Shear Stress
• Condition for dislocation motion:
10-4 GPa to 10-2 GPa
typically
• Crystal orientation can make
it easy or hard to move dislocation tR
= 0 l
=90° s tR = s /2 l
=45° f tR
= 0 f
=90° s
 maximum at  =  = 45º

17. Resolving the Applied Stress on a SLIP PLANE !
Shear Stress has to be resolved on to the slip planes as;
Shear Stress is needed for dislocations to move / slip
Dislocations can only move on slip planes, and these planes are rarely on axis with the applied force !
We should resolve the force applied in a tensile test, F, on to the cross-sectional area A where the slip is going to take place;

18. Critical Resolved Shear Stress => Slip in Single X’tals
Macroscopically;
Q: when do materials plastically deform / yield ?
Stress > YS
Q: How does plastic deformation take place ?
Dislocation Motion ( Elastic deformation ??)
Q: On what planes does dislocations move ?
Slip Planes
Q: At stress = YS, what would be the minimum resolved shear stress needed to act on dislocations to initiate dislocation motion, onset of yield/plastic deformation ?
HIMMM ! Lets think !!!

19. The Critical Resolved Shear Stress
The minimum shear stress required to initiate slip is termed:
the critical resolved shear stress

20. Single Crystal Slip Plastically stretched zinc single crystal.
Adapted from Fig. 7.9, Callister 7e.
A large number of dislocations are generated on slip planes, as they leave the system they form these “shear bands”
Adapted from Fig. 7.8, Callister 7e.

21. Ex: Deformation of single crystal
a) Will the single crystal yield?
b) If not, what stress is needed?
=60°
crss = 3000 psi
=35°
Adapted from Fig. 7.7, Callister 7e.
 = 6500 psi
So the applied stress of 6500 psi will not cause the crystal to yield.

22. Ex: Deformation of single crystal
What stress is necessary (i.e., what is the yield stress, sy)?
So for deformation to occur the applied stress must be greater than or equal to the yield stress

23. Slip Motion in Polycrystals
300 mm
• Stronger - grain boundaries pin deformations
• Slip planes & directions
(l, f) change from one
crystal to another.
• tR will vary from one
• The crystal with the
largest tR yields first.
• Other (less favorably
oriented) crystals
yield later.
Adapted from Fig. 7.10, Callister 7e.
(Fig is courtesy of C. Brady, National Bureau of Standards [now the National Institute of Standards and Technology, Gaithersburg, MD].)

24. Plastic Deformation in Polycrystalline Materials

25. Anisotropy in sy • Can be induced by rolling a polycrystalline metal
- before rolling
- after rolling
- anisotropic
since rolling affects grain
orientation and shape.
rolling direction
Adapted from Fig. 7.11, Callister 7e. (Fig is from W.G. Moffatt, G.W. Pearsall, and J. Wulff, The Structure and Properties of Materials, Vol. I, Structure, p. 140, John Wiley and Sons, New York, 1964.)
235 mm
- isotropic
since grains are
approx. spherical
& randomly
oriented.

26. Anisotropy in Deformation
• The noncircular end view shows
anisotropic deformation of rolled material.
end
view
3. Deformed
cylinder
plate
thickness
direction
Photos courtesy
of G.T. Gray III,
Los Alamos
National Labs. Used with
permission.
1. Cylinder of
Tantalum
machined
from a
rolled plate:
rolling direction
2. Fire cylinder
at a target.
side view

27. ANISOTROPY IN DEFORMATION
1. Cylinder of
Tantalum
machined
from a
rolled plate:
2. Fire cylinder
at a target.
3. Deformed
cylinder
Photos courtesy
of G.T. Gray III,
Los Alamos
National Labs. Used with
permission.
side view
end
view
plate
thickness
direction
• The noncircular end view shows:
anisotropic deformation of rolled material. 10

28. STRENGTHENING MECHANISMS
The ability of a metal to deform depends on the ability of dislocations to move with relative ease under loading conditions
Restricting dislocation motion will inevitably make the material stronger, need more force to induce same amount of deformation !
Mechanisms of strengthening in single-phase metals:
grain-size reduction
solid-solution alloying
strain hardening
Ordinarily, strengthening mechanisms reduces ductility, why ???

29. 4 STRATEGIES FOR STRENGTHENING: 1: REDUCE GRAIN SIZE
• Grain boundaries are
barriers to slip.
• Barrier "strength"
increases with
mis-orientation.
High-angle boundaries are better in blocking slip !
• Smaller grain size:
more barriers to slip.
Grain size can be changed by processing !
Adapted from Fig. 7.12, Callister 6e.
(Fig is from A Textbook of Materials Technology, by Van Vlack, Pearson Education, Inc., Upper Saddle River, NJ.)
Hall-Petch Equation :
Average grain size 7

30. GRAIN SIZE STRENGTHENING: AN EXAMPLE
• 70wt%Cu-30wt%Zn brass alloy
• Data:
Adapted from Fig. 7.13, Callister 6e.
(Fig is adapted from H. Suzuki, "The Relation Between the Structure and Mechanical Properties of Metals", Vol. II, National Physical Laboratory Symposium No. 15, 1963, p. 524.) 8

31. 4 Strategies for Strengthening: 2: Solid Solutions
• Impurity atoms distort the lattice & generate stress.
• Stress can produce a barrier to dislocation motion.
• Smaller substitutional
impurity
Impurity generates local stress at A and B that opposes dislocation motion to the right. A B
• Larger substitutional
impurity
Impurity generates local stress at C and D that opposes dislocation motion to the right. C D

32. Strategy #2: Solid Solutions
Alloyed metals are usually stronger than their pure base metals counter parts.
Why ? Interstitial or substitutional impurities in a solution cause lattice strain, aka distortions in the lattice
Then ?
Strain field around the impurities interact with dislocation strain fields and impede dislocation motion.
Impurities tend to diffuse and segregate around the dislocation core to find atomic sites more suited to their radii. This reduces the overall strain energy and “anchor” the dislocation.
Motion of the dislocation core away from the impurities moves it to a region of lattice where the atomic strains are greater, where lattice strains due to dislocation is no longer compensated by the impurity atoms.

33. Interactions of the Stress Fields
COMPRESSIVE
TENSILE
TENSILE
COMPRESSIVE

34. Interactions of the Stress Fields

35. Stress Concentration at Dislocations
Don’t move past one another – hardens material
Adapted from Fig. 7.4, Callister 7e.

36. Impurity Segregation
Impurities tend to segregate at energetically favorable areas around the dislocation core and partially decrease the overall stress field generated around the dislocation core.
However, when stress is applied more load is needed to move dislocations with impurity atoms segregated to its core !

37. Strengthening by Alloying
small impurities tend to concentrate at dislocations
reduce mobility of dislocation  increase strength
Adapted from Fig. 7.17, Callister 7e.

38. Strengthening by alloying
large impurities concentrate at dislocations on low density side
Adapted from Fig. 7.18, Callister 7e.

39. Ex: Solid Solution Strengthening in Copper
• Tensile strength & yield strength increase with wt% Ni.
Tensile strength (MPa)
wt.% Ni, (Concentration C)
200
300
400 10 20 30 40 50
Yield strength (MPa)
wt.%Ni, (Concentration C) 60
120
180 10 20 30 40 50
Adapted from Fig (a) and (b), Callister 7e.
• Empirical relation:
• Alloying increases sy and TS.

40. 4 Strategies for Strengthening: 3: Precipitation Strengthening
• Hard precipitates are difficult to shear.
Ex: Ceramics in metals (SiC in Iron or Aluminum).
Side View
precipitate
Top View
Slipped part of slip plane
Unslipped part of slip plane S
spacing
Large shear stress needed
to move dislocation toward
precipitate and shear it.
Dislocation
“advances” but
precipitates act as
“pinning” sites with
spacing S .
• Result:

41. Application: Precipitation Strengthening
• Internal wing structure on Boeing 767
Adapted from chapter-opening photograph, Chapter 11, Callister 5e. (courtesy of G.H. Narayanan and A.G. Miller, Boeing Commercial Airplane Company.)
• Aluminum is strengthened with precipitates formed
by alloying.
1.5mm
Adapted from Fig , Callister 7e.
(Fig is courtesy of G.H. Narayanan and A.G. Miller, Boeing Commercial Airplane Company.)

42. 4 Strategies for Strengthening: 4: Cold Work (%CW)
• Room temperature deformation.
• Common forming operations change the cross
sectional area:
Adapted from Fig. 11.8, Callister 7e.
-Forging A o d
force
die
blank
-Rolling
roll A o d
-Drawing
tensile
force A o d
die
-Extrusion
ram
billet
container
force
die holder
die A o d
extrusion

43. Dislocations During Cold Work
• Ti alloy after cold working:
0.9 mm
• Dislocations entangle
with one another
during cold work.
• Dislocation motion
becomes more difficult.
Adapted from Fig. 4.6, Callister 7e.
(Fig. 4.6 is courtesy of M.R. Plichta, Michigan Technological University.)

44. Result of Cold Work total dislocation length Dislocation density =
unit volume
Dislocation density =
Carefully grown single crystal
 ca. 103 mm-2
Deforming sample increases density
 mm-2
Heat treatment reduces density
 mm-2
Again it propagates through til reaches the edge
large hardening
small hardening s e y0 y1
• Yield stress increases
as rd increases:

45. RESULT OF COLD WORK • Dislocation density (rd) goes up:
Carefully prepared sample: rd ~ 103 mm/mm3
Heavily deformed sample: rd ~ 1010 mm/mm3
• Ways of measuring dislocation density:
40mm
Micrograph adapted from Fig. 7.0, Callister 6e. (Fig. 7.0 is courtesy of W.G. Johnson, General Electric Co.) OR
• Yield stress increases
as rd increases: 18

46. STRENGTHENING STRATEGY 4: COLD WORK (%CW)
• An increase in sy due to plastic deformation.
BUT actually # of dislocations are increasing !!!
• Curve fit to the stress-strain response: 22

47. Stress fields of dislocations interacting !
The strain fields around dislocations interact with each other. Hence, they exert force on each other.
Edge dislocations, when they are in the same plane, they repel each other if they have the same
sign (direction of the Burgers vector). WHY ?
They can attract and annihilate if they have opposite signs. PROVE !

48. Effects of Stress at Dislocations
Adapted from Fig. 7.5, Callister 7e.

49. IMPACT OF COLD WORK • Yield strength (s ) increases.
• Tensile strength (TS) increases.
• Ductility (%EL or %AR) decreases. y
Adapted from Fig. 7.18, Callister 6e. (Fig is from Metals Handbook: Properties and Selection: Iron and Steels, Vol. 1, 9th ed., B. Bardes (Ed.), American Society for Metals, 1978, p. 221.)
Stress
% cold work
Strain 21

50. Impact of Cold Work As cold work is increased
• Yield strength (sy) increases.
• Tensile strength (TS) increases.
• Ductility (%EL or %AR) decreases.
Adapted from Fig. 7.20, Callister 7e.

51. Cold Work Analysis Cu Cu Cu • What is the tensile strength &
=12.2mm
Copper
• What is the tensile strength &
ductility after cold working? D o
=15.2mm
% Cold Work
100
300
500
700 Cu 20 40 60
yield strength (MPa)
% Cold Work
tensile strength (MPa)
200 Cu
400
600
800 20 40 60
ductility (%EL)
% Cold Work 20 40 60 Cu s y
= 300MPa
300MPa
340MPa
TS = 340MPa 7%
%EL
= 7%
Adapted from Fig. 7.19, Callister 7e. (Fig is adapted from Metals Handbook: Properties and Selection: Iron and Steels, Vol. 1, 9th ed., B. Bardes (Ed.), American Society for Metals, 1978, p. 226; and Metals Handbook: Properties and Selection: Nonferrous Alloys and Pure Metals, Vol. 2, 9th ed., H. Baker (Managing Ed.), American Society for Metals, 1979, p. 276 and 327.)

52. s- e Behavior vs. Temperature
• Results for
polycrystalline iron:
-200C
-100C
25C
800
600
400
200
Strain
Stress (MPa)
0.1
0.2
0.3
0.4
0.5
Adapted from Fig. 6.14, Callister 7e.
• sy and TS decrease with increasing test temperature.
• %EL increases with increasing test temperature.
• Why? Vacancies
help dislocations
move past obstacles. 3
. disl. glides past obstacle
2. vacancies
replace
atoms on the
disl. half
plane
1. disl. trapped
by obstacle
obstacle

53. Effect of Heating After %CW
• 1 hour treatment at Tanneal...
decreases TS and increases %EL.
• Effects of cold work are reversed!
tensile strength (MPa)
ductility (%EL)
tensile strength
ductility
Recovery
Recrystallization
Grain Growth
600
300
400
500 60 50 40 30 20
annealing temperature (ºC)
200
100
700
• 3 Annealing
stages to
discuss...
Adapted from Fig. 7.22, Callister 7e. (Fig.
7.22 is adapted from G. Sachs and K.R. van Horn, Practical Metallurgy, Applied Metallurgy, and the Industrial Processing of Ferrous and Nonferrous Metals and Alloys, American Society for Metals, 1940, p. 139.)

54. Recovery tR Annihilation reduces dislocation density. • Scenario 1
Results from diffusion
extra half-plane
of atoms
Dislocations
annihilate
and form
a perfect
atomic
plane.
atoms
diffuse
to regions
of tension
• Scenario 2 tR
1. dislocation blocked;
can’t move to the right
Obstacle dislocation 3
. “Climbed” disl. can now
move on new slip plane 2
. grey atoms leave by
vacancy diffusion
allowing disl. to “climb”
4. opposite dislocations
meet and annihilate

55. Recrystallization • New grains are formed that:
-- have a small dislocation density
-- are smalller then initial cold worked ones
-- consume cold-worked grains.
33% cold
worked
brass
New crystals
nucleate after
3 sec. at 580C.
0.6 mm
Adapted from Fig (a),(b), Callister 7e. (Fig (a),(b) are courtesy of J.E. Burke, General Electric Company.)

56. Further Recrystallization
• All cold-worked grains are consumed.
After 4
seconds
After 8
0.6 mm
Adapted from Fig (c),(d), Callister 7e. (Fig (c),(d) are courtesy of J.E. Burke, General Electric Company.)

57. Grain Growth • At longer times, larger grains consume smaller ones.
• Why? Grain boundary area (and therefore energy)
is reduced.
After 8 s,
580ºC
After 15 min,
0.6 mm
Adapted from Fig (d),(e), Callister 7e. (Fig (d),(e) are courtesy of J.E. Burke, General Electric Company.)
• Empirical Relation:
elapsed time
coefficient dependent
on material and T.
grain diam.
at time t.
exponent typ. ~ 2
Ostwald Ripening

58. TR = recrystallization temperatureTR
TR = recrystallization temperature
Adapted from Fig. 7.22, Callister 7e.

59. Coldwork Calculations
A cylindrical rod of brass originally 0.40 in (10.2 mm) in diameter is to be cold worked by drawing. The circular cross section will be maintained during deformation. A cold-worked tensile strength in excess of 55,000 psi (380 MPa) and a ductility of at least 15 %EL are desired. Further more, the final diameter must be 0.30 in (7.6 mm). Explain how this may be accomplished.

60. Coldwork Calculations Solution
If we directly draw to the final diameter what happens?
Brass
Cold
Work D f
= 0.30 in D o
= 0.40 in

61. Coldwork Calc Solution: Cont.
420
540 6
For %CW = 43.8%
Adapted from Fig. 7.19, Callister 7e.
y = 420 MPa
TS = 540 MPa > 380 MPa
%EL = 6 < 15
This doesn’t satisfy criteria…… what can we do?

62. Coldwork Calc Solution: Cont.
380 12 15 27
Adapted from Fig. 7.19, Callister 7e.
For TS > 380 MPa
> 12 %CW
For %EL < 15
< 27 %CW
 our working range is limited to %CW = 12-27

63. Coldwork Calc Soln: Recrystallization
Cold draw-anneal-cold draw again
For objective we need a cold work of %CW  12-27
We’ll use %CW = 20
Diameter after first cold draw (before 2nd cold draw)?
must be calculated as follows: 
So after the cold draw & anneal D02=0.335m
Intermediate diameter =

64. Coldwork Calculations Solution
Summary:
Cold work D01= 0.40 in  Df1 = m
Anneal above D02 = Df1
Cold work D02= in  Df 2 =0.30 m
Therefore, meets all requirements
Fig 7.19 

65. Rate of Recrystallization
Hot work  above TR
Cold work  below TR
Smaller grains
stronger at low temperature
weaker at high temperature
log t
start
finish
50%
No Strain hardening occurs
TR ~ 0.3 Tm-0.7 Tm
TR depends on %CW
Decrease with increasing % CW

66. Summary • Dislocations are observed primarily in metals and alloys.
• Strength is increased by making dislocation
motion difficult.
• Particular ways to increase strength are to:
--decrease grain size
--solid solution strengthening
--precipitate strengthening
--cold work
• Heating (annealing) can reduce dislocation density
and increase grain size. This decreases the strength.

67. ANNOUNCEMENTS Reading: Chapter 7
Core Problems: 7.6, 7.7, 7.13 (see page 183-4), 7.14, 7.23, 7.31, 7.41 (figure 7.25)
Bonus Problems: 7.40, 7.36, 7.39
Due date is April 3th