Abstract
The emergence of shear inhomogeneity across grain boundaries during severe shear deformation in Cu at the micrometer length-scales is demonstrated through in situ imaging inside a scanning electron microscope. The deformation mechanics during machining is found to be orientation dependent. Microstructure refinement from severe plastic deformation in confined volumes is entirely suppressed in certain orientations but results in a characteristic ultrafine structure in others. Rampant ductile fracture is found to nucleate at some grain boundaries due to elevated dislocation densities, and this failure mechanism is imprinted on the freshly generated surface, which limits the precision of machining-based processes (e.g., diamond turning) in nanometrically-smooth roughness profiles.
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