Fracture of the C15 CaAl2 Laves phase at small length scales

The cubic C15 CaAl2 Laves phase is an important brittle intermetallic precipitate in ternary Mg-Al-Ca structural alloys. Although knowledge of the mechanical properties of the co-existing phases is essential for the design of improved alloys, the fracture toughness of the C15 CaAl2 intermetallic has not yet been studied experimentally due to limitations posed by macroscale testing of defect-free specimens. Here, miniaturised testing techniques like micropillar splitting and microcantilever bending methods are used to experimentally determine the fracture toughness of the CaAl2 Laves phase. It is found that the toughness value of similar to 1 MPa.root m obtained from pillar splitting with a sharp cube corner geometry is largely insensitive to sample heat treatment, the ion beam used during fabrication, micropillar diameter, and surface orientation. From correlative nanoindentation and electron channelling contrast imaging supported by electron backscatter diffraction, fracture is observed to take place mostly on {011} planes. Atomistic fracture simulations on a model C15 NbCr2 Laves phase showed that the preference of {011} cleavage planes over the more energetically favourable {111} planes is due to lattice trapping and kinetics controlling fracture planes in complex crystal structures, which may provide insights into the experimental results for CaAl2. Using rectangular microcantilever bending tests where the notch plane was misoriented to the closest possible {112} cleavage plane by similar to 8 degrees and the closest {001}, {011}, and {111} planes by > 20 degrees, a toughness of similar to 2 MPa.root m was determined along with the electron microscopy observation of significant deviations of the crack path, demonstrating that preferential crystallographic cleavage planes determine the toughness in this material. Further investigation using pentagonal microcantilevers with precise alignment of the notch with the cleavage planes revealed