A comprehensive study of grain size effect on twins, slips and work hardening of rhenium during tension was conducted using EBSD and SEM analysis. Slip/twinning trace and Schmid factor (SF) were analyzed to elucidate the activities of deformation modes. The deformation behavior was found to be sensitive to grain size. Non-basal slips and {112¯1} <1¯1¯26> extension twins were found to be the dominated deformation modes in the samples with large grain size. Large KAM values are located in twin GBs and severely deformed grains. Basal slip with low SFs was also activated to adapt strain-compatibility. With the decrease of grain size, non-basal slip was suppressed and an obvious transition from non-basal to basal slip-dominated flow occurred. The pure Re with coarse grain size (d = 67 μm) had a high elongation (27.6%) and ultimate strength (1168 MPa). In contrast, intergranular compatibility became difficult with decreasing grain size due to the progressively lower activation ability of deformation mechanisms, resulting in a reduction of ductility and ultimate strength. The exceptionally high work hardening rate of rhenium was mainly attribute to twin formation and basal slip activity during the initial straining. With the increase of grain size, high density cross-slip and twins provide additional work hardening, leading to extrapolated work hardening limit.
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