Grain polydispersity and coherent crystal reorientations are features to foster stress hotspots in polycrystalline alloys under load.

The mechanical properties of metallic alloys are controlled through the design of their polycrystalline structure via heat treatments. For single-phase microstructures, they aim to achieve a particular average grain diameter to leverage stress hardening or softening. The stochastic nature of the recrystallization process generates a grain size distribution, and the randomness of the crystallographic orientation determines the anisotropy of a mechanical response. We developed a multiscale computational formalism to capture the collective mechanical response of polycrystalline microstructures at unprecedented length scales. We found that for an averaged grain size, the mechanical response is highly dependent on the grain size distribution. The simulations reveal the topological conditions that promote coherent grain texturization and grain growth inhibition during stress relaxation. We identify the microstructural features that are responsible for the appearance of stress hotspots. Our results provide the elusive evidence of how stress hotspots are ideal precursors for plastic and creep failure.