Hydrogen drastically embrittles high-strength aluminum alloys, which impedes efforts to develop ultrastrong components in the aerospace and transportation industries. Understanding and utilizing the interaction of hydrogen with core strengthening elements in aluminum alloys, particularly nanoprecipitates, are critical to break this bottleneck. Herein, we show that hydrogen embrittlement of aluminum alloys can be largely suppressed by switching nanoprecipitates from the η phase to the T phase without changing the overall chemical composition. The T phase strongly traps hydrogen and resists hydrogen-assisted crack growth, with a more than 60% reduction in the areal fractions of cracks. The T phase-induced reduction in the concentration of hydrogen at defects and interfaces, which facilitates crack growth, primarily contributes to the suppressed hydrogen embrittlement. Transforming precipitates into strong hydrogen traps is proven to be a potential mitigation strategy for hydrogen embrittlement in aluminum alloys.

Hydrogen embrittlement (HE) impairs the durability of aluminium (Al) alloys and hinders their use in a hydrogen economy^1,2,3. Intermetallic compound particles in Al alloys can trap hydrogen and mitigate HE⁴, but these particles usually form in a low number density compared with conventional strengthening nanoprecipitates. Here we report a size-sieved complex precipitation in Sc-added Al–Mg alloys to achieve a high-density dispersion of both fine Al₃Sc nanoprecipitates and in situ formed core-shell Al₃(Mg, Sc)₂/Al₃Sc nanophases with high hydrogen-trapping ability. The two-step heat treatment induces heterogeneous nucleation of the Samson-phase Al₃(Mg, Sc)₂ on the surface of Al₃Sc nanoprecipitates that are only above 10 nm in size. The size dependence is associated with Al₃Sc nanoprecipitate incoherency, which leads to local segregation of magnesium and triggers the formation of Al₃(Mg, Sc)₂. The tailored distribution of dual nanoprecipitates in our Al–Mg–Sc alloy provides about a 40% increase in strength and nearly five times improved HE resistance compared with the Sc-free alloy, reaching a record tensile uniform elongation in Al alloys charged with H up to 7 ppmw. We apply this strategy to other Al–Mg-based alloys, such as Al–Mg–Ti–Zr, Al–Mg–Cu–Sc and Al–Mg–Zn–Sc alloys. Our work showcases a possible route to increase hydrogen resistance in high-strength Al alloys and could be readily adapted to large-scale industrial production.

Steel products typically undergo intricate manufacturing processes, commencing from the liquid phase, with casting, hot rolling, and laminar cooling being among the most crucial processes. In the background of carbon neutrality, thin-slab casting and direct rolling (TSCR) technology has attracted significant attention, which integrates the above three processes into a simpler and more energy-efficient sequence compared to conventional methods. Multi-scale computational modeling and simulation play a crucial role in steel design and optimization, enabling the prediction of properties and microstructure in final steel products. This approach significantly reduces the time and cost of production compared to traditional trial-and-error methodologies. This study provides a review of cross-scale simulations focusing on the casting, hot-rolling, and laminar cooling processes, aiming at presenting the key techniques for realizing cross-scale simulation of the TSCR process.