Researchers at the University of California, Irvine have advanced our understanding of how metals deform under stress by challenging a decades-old theory about slip band formation. Their findings provide crucial insights into the mechanical behavior of cutting-edge materials used in energy systems, space missions, and nuclear technologies.

In a recent study published in Nature Communications, scientists from UC Irvine's Samueli School of Engineering revealed the existence of extended slip bands—structural features that deviate from the established Frank–Read model from the 1950s. That model explains slip band formation as a result of continuous dislocation multiplication at active sources. However, the UC Irvine team discovered that these extended bands arise instead from the deactivation of one dislocation source and the sequential activation of new ones.

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This breakthrough was made possible through mechanical compression experiments on micropillars of a chromium-cobalt-nickel (CrCoNi) alloy, a material recognized as one of the toughest ever developed. Using high-resolution scanning transmission electron microscopy and large-scale atomistic simulations, the team observed slip bands forming at the atomic scale. Their analysis showed that confined slip bands appeared as narrow, low-defect glide zones, while extended slip bands exhibited a high density of planar defects.

"Despite over 70 years of research since the Frank–Read theory was introduced, the complete picture of slip band formation remained elusive," said Penghui Cao, corresponding author and associate professor of mechanical and aerospace engineering at UC Irvine. "Our ability to track these phenomena down to the atomic level sheds light on how collective dislocation movements and localized deformation occur in advanced materials."

Cao emphasized that localized strain, known as deformation banding, is a widespread phenomenon found in both engineered and natural systems—from metals and crystalline solids to granular materials and even geological fault zones under compression.

“With the emergence of advanced materials like the CrCoNi alloy, understanding their mechanical behavior under extreme conditions is essential,” Cao added. “This foundational research paves the way for designing new materials with precisely engineered properties, which are urgently needed in fields such as energy, aerospace, and beyond.”