Beam deflection experiments were used to systematically examine size effects on the low cyclic fatigue (LCF) deformation behaviour of micro-sized bending beams of copper (Cu) single crystals oriented for single slip, critical and coplanar double slip. We present cyclic hardening curves and fatigue surface roughness, as well as dislocations structures of the micro-sized beams with sizes between 1 and 15 µm. A clear crystal orientation and size effect on the cyclic hardening curves, surface roughness, and the dislocation microstructures were observed. Based on the experimental results, the fatigue damage in single slip orientations clearly decreased with decreasing the sample size, however, below a critical size regime, the surface damage suddenly increases. Additionally, samples with sizes larger than 5 µm clearly revealed, besides PSBs-like structures, the emergence of kink bands leading to larger surface roughness in comparison to the smaller ones. Fatigue surface damages in microcrystals oriented for critical double slip became more prevalent compared to single slip orientations. Quantitatively, the correlation of the fatigue surface damage was also demonstrated with the formation of PSBs-like structures.
Keywords: PSBs-like structures; dislocation dipole; fatigue; kink bands.