The important benefits of ultrafine-grained (UFG) alloys for various applications stem from their enhanced superplastic properties. However, decreasing the temperature of superplasticity and providing superplastic forming at lower temperatures and higher strain rates is still a priority. Here, we disclose, for the first time, the mechanism by which grain boundary sliding and rotation are enhanced, when UFG materials have grain boundary segregation of specific alloying elements. Such an approach enables achieving superplasticity in commercial Al alloys at ultralow homologous temperatures below 0.5 (i.e. below 200°C), which is important for developing new efficient technologies for manufacturing complex-shaped metallic parts with enhanced service properties. IMPACT STATEMENT For the first time, ultralow-temperature superplasticity is found in commercial 7xxx Al alloy. This discovery enables the development of new technologies for the superplastic forming of complex-shaped products with enhanced service properties.

In the last three decades, several severe plastic deformation (SPD) procedures have been developed and applied in materials science to create bulk, ultrafine-grained (UFG) structures. As a consequence of the SPD, not only submicron and even nanometer grain sizes can be obtained, but also new grain boundaries with non-equilibrium structures in a material may be formed. Therefore, both the strength and ductility of the UFG materials can change significantly compared to the coarse-grained counterparts. This review is focused on unusual mechanical behaviors of UFG Al and Al alloys, associated with grain boundary structure and segregations which are responsible for the modification of the Hall-Petch relationship and the so-called size-effect for UFG structure. Unusually high strain rate sensitivity, intensive grain boundary sliding and superplasticity at low temperature are described and surveyed. In addition, innovation potential of these phenomena is also briefly considered.

Al–Zn alloys having different Zn contents of 2, 5, 10 and 30 wt% were processed by high-pressure torsion (HPT) to produce ultrafine-grained (UFG) materials. Microstructural features of these UFG Al–Zn alloys were investigated using depth-sensing indentations, focused ion beam (FIB), scanning electron microscopy (SEM) and differential scanning calorimetry (DSC). Emphasis was placed on the microstructure evolution of the alloys with different Zn-concentration which demonstrated substantially different mechanical behavior, exhibiting superductility with increasing Zn content. It was shown that in every case, HPT resulted decomposition in the microstructure, but there is a significant difference between the microstructures of alloys with low and high Zn content. Based on the microstructural observations, a scenario is proposed about that how the decomposed microstructure developed during HPT process in low- and high Zn-containing Al–Zn alloys, influencing their mechanical behavior. Graphical abstract

A homogenized, supersaturated AlZnMgZr alloy was processed via severe plastic deformation (SPD) using a high-pressure torsion (HPT) technique for different revolutions at room temperature to obtain an ultrafine-grained (UFG) microstructure. The microstructure and mechanical properties of the UFG samples were then studied using transmission electron microscopy (TEM), differential scanning calorimetry (DSC), and tensile and hardness measurements. The main purpose was to study the effect of shear strain on the evolution of the microstructure of the investigated alloy. We found a very interesting evolution of the decomposed microstructure in a wide range of shear strains imposed by HPT. While the global properties, such as the average grain size (~200 nm) and hardness (~2200 MPa) appeared unchanged, the local microstructure was continuously transformed. After 1 turn of HPT, the decomposed UFG structure contained relatively large precipitates inside grains. In the sample processed by five turns in HPT, the segregation of Zn atoms into grain boundaries (GBs) was also observed. After 10 turns, more Zn atoms were segregated into GBs and only smaller-sized precipitates were observed inside grains. The intensive solute segregations into GBs may significantly affect the ductility of the material, leading to its ultralow-temperature superplasticity. Our findings pave the way for achieving advanced microstructural and mechanical properties in nanostructured metals and alloys by engineering their precipitation and segregation by means of applying different HPT regimes.

Low temperature tensile and impression creep tests were carried out on an ultrafine-grained 7xxx series Al–4.8Zn–1.2 Mg–0.14Zr (wt%) alloy, which can be deformed for maximum elongation of about 200% at 150 °C. The characteristics of the deformation process, such as the strain rate sensitivity (SRS) and activation energy (Q) were determined by considering also the effect of threshold stress. Relatively high SRS of $$\sim$$∼ 0.35 and low activation energy of $$\sim$$∼ 92 kJ/mole were obtained, confirming the super ductility of the investigated ultrafine-grained alloy in the low temperature region between 140 and 160 °C.Graphical abstract