Mapping stress and microstructure in industrial metals

The development and processing of metals and alloys are crucial to modern industries such as aerospace, automotive, construction, and energy. The macroscopic properties of metal components – such as strength, ductility, and thermal conductivity – depend heavily on their mechanical response under stress. Metals are polycrystalline materials, consisting of multiple single-crystal grains, each with a unique 3D orientation, morphology, and stress state. This leads to a complex hierarchy of mechanical behaviour, from macroscopic scales to grain ensembles and intra-grain strains and stresses. The distinct elasto-plastic signature of a metal arises from this interplay of microscopic properties.

Historically, industrial processes like rolling, extrusion, and forging have relied on a macroscopic understanding of plastic deformation to engineer desired metal properties. Investigating how microscopic deformation affects performance can significantly benefit industry, helping design new, more durable, and efficient materials. Electron microscopy techniques are widely used to probe metal microstructures but are often limited to thin films or surface layers.