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<p>Lightweight, high-strength structural materials are component enablers in transportation and aerospace, reducing carbon footprints and enhancing fuel efficiency. Cast aluminium alloys, mainly based on eutectic compositions, make up ∼&#xa0;85% of these materials but often fail catastrophically due to inefficient load transfer across the interfaces between the brittle eutectic phase and the ductile matrix. Here, we discovered that promoting a superlattice nano-layer (SNL) around the eutectic fibres, achieved by adding Zr to an Al-Gd near-eutectic alloy, enables excellent load transfer capabilities, resulting in a ∼ 400% increase in tensile ductility. The primary α-Al matrix also contains a high number density of superlattice core-shell nano-particles. This exceptional increase in formability is attributed to the ability of the SNL to prevent dislocations from accumulating at the weak and brittle eutectic fibre/matrix interfaces, thereby avoiding stress concentrations that would otherwise initiate fibre breakage and debonding. The core-shell nano-particles in α-Al cause a large number of dislocation cross/multiple-slips on {111} planes, forming ultra-fine (∼ 12 nm) dislocation networks that leverage substantial plastic strain accumulation. This atomic interface design overcomes the ductility limitations of cast-eutectic alloys, enabling them for structural applications.</p>

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Strength-ductility synergy in lightweight aluminium alloys with nano-layered fibres and core-shell nano-particles

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年6月23日

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  • Hemant Kumar,
  • Praveen Kumar,
  • Dierk Raabe,
  • Baptiste Gault,
  • Surendra Kumar Makineni

摘要

Lightweight, high-strength structural materials are component enablers in transportation and aerospace, reducing carbon footprints and enhancing fuel efficiency. Cast aluminium alloys, mainly based on eutectic compositions, make up ∼ 85% of these materials but often fail catastrophically due to inefficient load transfer across the interfaces between the brittle eutectic phase and the ductile matrix. Here, we discovered that promoting a superlattice nano-layer (SNL) around the eutectic fibres, achieved by adding Zr to an Al-Gd near-eutectic alloy, enables excellent load transfer capabilities, resulting in a ∼ 400% increase in tensile ductility. The primary α-Al matrix also contains a high number density of superlattice core-shell nano-particles. This exceptional increase in formability is attributed to the ability of the SNL to prevent dislocations from accumulating at the weak and brittle eutectic fibre/matrix interfaces, thereby avoiding stress concentrations that would otherwise initiate fibre breakage and debonding. The core-shell nano-particles in α-Al cause a large number of dislocation cross/multiple-slips on {111} planes, forming ultra-fine (∼ 12 nm) dislocation networks that leverage substantial plastic strain accumulation. This atomic interface design overcomes the ductility limitations of cast-eutectic alloys, enabling them for structural applications.