─The extreme miniaturization in modern technology calls for deeper insights into the non-conventional, fluctuation dominated mechanics of materials at micro-to nano-scales. Both experiments and simulations show that sub-micron face-centered-cubic (FCC) crystals exhibit high yield strength, which is, however, compromised by intermittent, power law distributed strain fluctuations, typical of 'wild plasticity'. At macro-scales, the same bulk materials show 'mild plasticity' characterized by bounded, uncorrelated fluctuations. Both anomalous strength andintermittency appear therefore as size effects. While the former is highly desirable, the latter is detrimental because stochastic dislocation avalanches interfere with forming processes and endanger structural stability. In this paper we show that defectiveness, which is used in classical metallurgy to harden materials, can be used at sub-micron scales to suppress intermittent fluctuations. We quantify the coexistence of 'wild' and 'mild' fluctuations in compressed Al alloys micro-pillars, demonstrate that the statistical nature of fluctuations is determined by sample size, and propose quantitative strategies allowing one to temper plastic intermittency by artificially tailored disorder. Our experimental results are rationalized using a theoretical framework which quantifies the competition between external (size related) and internal (disorder related) length scales.

The microstructure evolution due to thermomechanical treatment of metals can largely be described by viscoplastic deformation, nucleation and grain growth. These processes take place over different length and time scales which present significant challenges when formulating simulation models. In particular, no overall unified field framework exists to model concurrent viscoplastic deformation and recrystallization and grain growth in metal polycrystals. In this work a thermodynamically consistent diffuse interface framework incorporating crystal viscoplasticity and grain boundary migration is elaborated.The Kobayashi-Warren-Carter (KWC) phase field model is extended to incorporate the full mechanical coupling with material and lattice rotations and evolution of dislocation densities. The Cosserat crystal plasticity theory is shown to be the appropriate framework to formulate the coupling between phase field and mechanics with proper distinction between bulk and grain boundary behaviour.