The review is concerned with the use of miniature specimens to identify the mechanical/creep properties of metals and alloys. It is not intended to consider the nanoscales, which have been reviewed elsewhere, but focus on the size ranges and forms that are of use to areas such as alloy development, surveillance monitoring, effects of irradiation, properties of weld structures and remaining life. For many of these cases, there are technical advantages in the use of small specimens. Where possible, available reviews in this area are used and identified. The needs for small specimen sizes are considered, and the wide range of sizes of both conventional and more unusual specimen designs is reviewed. The potential effects of specimen size are considered: the microstructural features of the material, the effect of constraint and the actual region of the specimen that is undergoing deformation, and finally statistical approaches. The results of published studies are considered under the general groupings of yield/deformation behaviour, creep properties, toughness and fatigue, with an examination of the current state of interpretation of data from mini-specimens because interpretation is one of the key areas of interest. Finally, the current status of each area is considered, as certain designs of specimen will be better suited to answering specific technical questions. The need for standards for specific designs is also examined.

The finite element (FE) method has been applied to simulate residual axial and hoop stresses generated in the weld region and heat-affected zone of an axisymmetric 50-bead circumferentially butt-welded P91 steel pipe, with an outer diameter of 145 mm and wall thickness of 50 mm. The FE simulation consists of a thermal analysis and a sequentially coupled structural analysis. Solid-state phase transformation (SSPT), which is characteristic of P91 steel during welding thermal cycles, has been modelled in the FE analysis by allowing for volumetric changes in steel and associated changes in yield stress due to austenitic and martensitic transformations. Phase transformation plasticity has also been taken into account. The effects of post-weld heat treatment (PWHT) have been investigated, including those of heat treatment holding time. Residual axial and hoop stresses have been depicted through the pipe wall thickness as well as along the outer surface of the pipe. The results indicate the importance of including SSPT in the simulation of residual stresses during the welding of P91 steel as well as the significance of PWHT on stress relaxation.

The small punch creep testing method is highly complex and involves interactions between a number of non-linear processes. The deformed shapes that are produced from such tests are related to the punch and specimen dimensions and to the elastic, plastic, and creep behaviour of the test material, under contact and large deformation conditions, at elevated temperature. Owing to its complex nature, it is difficult to interpret the small punch test creep data in relation to the corresponding uniaxial creep behaviour of the material. One of the aims of this paper is to identify the important characteristics of the creep deformation resulting from ‘localized’ deformations and from the ‘overall’ deformation of the specimen. Following this, the results of approximate analytical and detailed finite element analyses of small punch tests are investigated. It is shown that the regions of the uniaxial creep test curves dominated by primary, secondary, and tertiary creep are not those that are immediately apparent from the displacement versus time records produced during a small punch test. On the basis of the interpretation of the finite element results presented, a method based on a reference stress approach is proposed for interpreting the results of small punch test experimental data. Future work planned for the interpretation of small punch tests data is briefly addressed.