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<p>Achieving exceptional strength in lightweight Mg-RE alloys remains a critical challenge, requiring processing routes specifically designed to generate and stabilize high-density dislocation networks. In this context, this work examined the impact of multi-stage thermomechanical processing on the microstructure, mechanical properties, and dislocation density of the Mg-Gd-Y-Zn-Zr (GWZ821) alloy. An exceptional ultimate tensile strength of ~ 408&#xa0;MPa was achieved in a GWZ821 alloy through a multi-stage process involving double extrusion, hot rolling, and aging. This processing route produced a refined bimodal microstructure with an average grain size of ~ 2&#xa0;μm. The strengthening mechanism is a synergistic combination of grain-boundary pinning and intense dislocation hardening. Crucially, detailed TEM analysis revealed that the high dislocation density is dominated by basal &lt;a&gt; slip systems. This establishes a direct link between the specific thermomechanical path and the activation of potent strengthening mechanisms, offering a clear strategy for engineering advanced, high-performance magnesium alloys.</p> Graphic Abstract <p></p>

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Microstructural Evolution and Strengthening Mechanisms in a Mg-Gd-Y-Zn-Zr Alloy via Multi-stage Thermomechanical Processing

  • 期刊论文

  • 发表日期：

    2026年1月12日

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  • Jinjun Wang,
  • Muhammad Abubaker Khan,
  • Han Wang,
  • Zhexuan Huang,
  • Mohamed A. Afifi,
  • Jingyuan Li

摘要

Achieving exceptional strength in lightweight Mg-RE alloys remains a critical challenge, requiring processing routes specifically designed to generate and stabilize high-density dislocation networks. In this context, this work examined the impact of multi-stage thermomechanical processing on the microstructure, mechanical properties, and dislocation density of the Mg-Gd-Y-Zn-Zr (GWZ821) alloy. An exceptional ultimate tensile strength of ~ 408 MPa was achieved in a GWZ821 alloy through a multi-stage process involving double extrusion, hot rolling, and aging. This processing route produced a refined bimodal microstructure with an average grain size of ~ 2 μm. The strengthening mechanism is a synergistic combination of grain-boundary pinning and intense dislocation hardening. Crucially, detailed TEM analysis revealed that the high dislocation density is dominated by basal <a> slip systems. This establishes a direct link between the specific thermomechanical path and the activation of potent strengthening mechanisms, offering a clear strategy for engineering advanced, high-performance magnesium alloys.

Graphic Abstract