An AZ80 alloy with ultra-high strength and good ductility has been successfully prepared by a novel processing route of combining extrusion and caliber rolling. The caliber rolled (CRed) AZ80 alloy has a necklace grain structure with ultrafine dynamic recrystallized (DRXed) grains formed around the micro-scale deformed grains, which is remarkably different from the uniform microstructure of as-extruded sample free from caliber rolling. In addition, both the deformed region and the DRXed part in CRed AZ80 alloy exhibit more random basal texture than that of the as-extruded sample. Furthermore, the CRed AZ80 alloy demonstrates an excellent comprehensive mechanical property with the ultimate tensile strength of 446MPa and elongation of 13%, respectively. These good mechanical properties of CRed AZ80 alloy can be attributed to the synthetic effects of necklace bimodal microstructure containing ultra-fine grains, profuse Mg₁₇Al₁₂ precipitates, and the modified texture.

Improving the mechanical properties of Mg alloys is of great significance for their wide application. A micro-alloyed Mg-1.45Bi-0.79Ca alloy (in wt.%) exhibiting a high tensile yield strength of 394 ± 5 MPa and a moderate elongation of 6.6 ± 0.6% was fabricated by single pass extrusion. The superior high strength is mainly attributed to the synergy effects of ultra-fine dynamic recrystallized grains; numerous Mg₂Ca, Mg₃Bi₂, and Mg₂Bi₂Ca nano-precipitates; residual dislocations; sub-grain boundaries; as well as strong fibre texture in the extrusion direction.

Aiming to develop low-cost Mg alloys with good mechanical properties, a new Mg-6Bi-3Al-1Zn (wt.%, BAZ631) alloy having a high ultimate tensile strength of ~402 MPa and an elongation of ~15% was fabricated by single pass extrusion. The as-extruded BAZ631 alloy demonstrates an almost fully dynamic recrystallized microstructure with an average grain size of ~2.9 μm. Moreover, both nano-scale Mg₃Bi₂ and Mg₁₇Al₁₂ precipitates were found dispersed in the matrix. These excellent mechanical properties are attributed to the combined effects of grain boundary strengthening, dispersion and precipitation strengthening induced by both micro and nanoscale second phase particles, and solid-solution strengthening. This high strength and good ductile Mg-Bi based alloy without rare-earth elements addition is expected to inspire a new alloy design strategy for fabricating high performance Mg products for larger-scale industrial applications.

An exceptionally high-strength rare-earth-free Mg–8Al–3Bi (AB83) alloy was successfully fabricated via extrusion and caliber rolling. After three-pass caliber rolling, the homogenous microstructure of the as-extruded AB83 alloy was changed to a necklace-like bimodal structure consisting of ultra-fine dynamic recrystallized (DRXed) grains and microscale deformed grains. Additionally, both Mg₁₇Al₁₂ and Mg₃Bi₂ nanoprecipitates, undissolved microscale Mg₁₇Al₁₂, and Mg₃Bi₂ particles were dispersed in the matrix of caliber-rolled (CRed) AB83 alloy. The CRed AB83 sample demonstrated a slightly weakened basal texture, compared with that of the as-extruded sample. Consequently, CRed AB83 showed a tensile yield strength of 398 MPa, an ultimate tensile strength of 429 MPa, and an elongation of 11.8%. The superior mechanical properties of the caliber-rolled alloy were mainly originated from the combined effects of the necklace-like bimodal microstructure containing ultra-fine DRXed grains, the homogeneously distributed nanoprecipitates and microscale particles, as well as the slightly modified basal texture.

A Mg-1.32Bi-0.72Ca (BX11) alloy having bimodal grain structure was successfully prepared by a novel processing route of combining extrusion and three-pass caliber rolling. The first extruded and then caliber-rolled (E-CRed) alloy demonstrates a necklace-like grain structure with ultrafine grains formed around the microscale deformed grains, which is remarkably different from the uniform microstructure of the as-extruded alloy. In addition, the E-CRed BX11 alloy exhibits strong basal texture which is mainly original from the microscale deformed grains. Furthermore, the E-CRed BX11 alloy demonstrates excellent comprehensive mechanical properties, with an ultra-high yield strength of 351 MPa and a good elongation to failure of 13.2%. The significant strength improvement can be mainly attributed to the significant grain refinement and much stronger basal texture compared with the as-extruded sample.