Slip localization is widely observed in metallic polycrystals after tensile deformation, cyclic deformation (persistent slip bands) or pre-irradiation followed by tensile deformation (channels). Such strong deformation localized in thin slip bands induces local stress concentrations in the quasi-elastic matrix around, at the intersections between slip bands and grain boundaries where microcracks are often observed.Since the work of Stroh, such stress fields have been modeled using the dislocation pile-up theory which leads to stress singularities similar to the LEFM ones. The Griffith criterion has then been widely applied, leading usually to strong underestimations of the macroscopic stress for microcrack nucleation.In fact, slip band thickness is finite: 50–1000nm depending on material, temperature and loading conditions. Then, many slip planes are plastically activated through the thickness. Stress fields have probably been overestimated using the pile-up theory which assumes that all dislocations are located on the same atomic plane. To evaluate more realistic stress fields, crystalline finite element (FE) computations are carried out using microstructure inputs (slip band aspect ratio and spacing). Slip bands (low critical resolved shear stress) are embedded in an elastic matrix. The following results are obtained concerning grain boundary normal stress fields:–strong influence of slip band thickness close to the slip band corner, which is not accounted for by the pile-up theory. But far away, the thickness has a negligible effect and the predicted stress fields are close to the one predicted by the pile-up theory,–analytical formulae are deduced from the numerous FE computation results which allows the prediction of surface/bulk slips as well as grain boundary stress fields. Slip band plasticity parameters, slip band length and thickness, Schmid factor and remote stress are taken into account. The dependence with respect to the various parameters can be understood in the framework of matching expansions usually applied to cracks with V notches of finite thickness,–as the exponent of the GB stress close-field is lower than the pile-up or crack one, that is 0.5, the Griffith criterion may not be used for GB microcrack prediction in case of finite thickness. That is why finite crack fracture mechanics is used together with both energy and stress criteria,–the pile-up theory leads to large underestimation of the critical remote stress leading to GB microcrack nucleation measured in the case of pre-irradiated austenitic stainless steels subjected to tensile loading in inert environment, probably because of the overestimation of the local GB stress field. And the critical remote stress computed using the proposed modeling of slip bands of finite thickness is much closer to the experimental values.
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