Plastic deformation of micron-scale crystalline materials differs considerably from bulk samples as it is characterized by stochastic strain bursts. To obtain a detailed picture of the intermittent deformation phenomena, numerous micron-sized specimens must be fabricated and tested. An improved focused ion beam fabrication method is proposed to prepare non-tapered micropillars with excellent control over their shape. Moreover, the fabrication time is less compared with other methods. The in situ compression device developed in our laboratory allows high-accuracy sample positioning and force/displacement measurements with high data sampling rates. The collective avalanche-like motion of the dislocations is observed as stress decreases on the stress–strain curves. An acoustic emission (AE) technique was employed for the first time to study the deformation behavior of micropillars. The AE technique provides important additional in situ information about the underlying processes during plastic deformation and is especially sensitive to the collective avalanche-like motion of the dislocations observed as the stress decreases on the deformation curves.

Pure polycrystalline cobalt is systematically thermally treated in order to assess the effect of the microstructure on the compression behavior. Isothermal annealing of the as-drawn material leads to recrystallization and grain growth dependent on the annealing temperature (600–1100 ${}^{\circ }$C). Consequently, the yield strength decreases and the fracture strain increases as a function of rising grain size; the content of the residual fcc phase is ~6–11%. Subsequent thermal cycling around the transition temperature is applied to further modify the microstructure, especially in terms of the fcc phase content. With the increasing number of cycles, the grain size further increases and the fraction of the fcc phase significantly drops. At the same time, the values of both the yield strength and fracture strain somewhat decrease. An atypical decrease in the fracture strain as a function of grain size is explained in terms of decreasing fcc phase content; the stress-induced fcc→hcp transformation can accommodate a significant amount of plastic strain. Besides controlling basic material parameters (e.g., grain size and texture), adjusting the content of the fcc phase can thus provide an effective means of mechanical performance optimization with respect to particular applications.