High-performance lightweight materials are urgently needed because of energy savings and emission reduction. Here, we design a new steel with a low density of 6.41 g/cm³, which is a 20% weight reduction compared to the conventional steel. The mechanical properties and microstructures of the steels prepared with different routes are systematically explored by utilizing uniaxial tensile testing and transmission electron microscopy. The steel processed by cold rolling and recrystallization annealing at 950 °C for 15 min shows an ultra-high yield strength of 1241 ± 10 MPa, while retaining a good ductility of 38 ± 1%. The high yield strength is mainly related to the synergistic precipitation strengthening introduced by nanoscale B2 and κ′-carbides. It is encouraging to notice that the yield strength increased without scarifying ductility, compared to the ST steel. The key reason is that the high strain hardening rate is activated by combined factors, including the blockage of numerous twins and nanoscale B2 to the dislocation movements, and dynamic slip band refinement. This study is instructive for concurrently enhancing the strength and ductility of austenitic lightweight steels with fully recrystallized grains and dual nano-precipitates.

A medium-carbon low-alloy steel was prepared via the asymmetric rolling process with different ratios of upper and down roll velocities. Subsequently, the microstructure and mechanical properties were explored by using SEM, EBSD, TEM, tensile tests and nanoindentation. The results show that asymmetrical rolling (ASR) can significantly improve strength while retaining good ductility compared with conventional symmetrical rolling. The yield strength and tensile strength of the ASR-steel are 1292 ± 10 MPa and 1357 ± 10 MPa, respectively, which are higher than the values of 1113 ± 10 MPa and 1185 ± 10 MPa for the SR-steel. The ASR-steel retains good ductility of 16.5 ± 0.5%. The significant increase in strength is related to the joint actions of the ultrafine grains, dense dislocations and a large number of nanosized precipitates. This is mainly because of the introduction of extra shear stress on the edge under asymmetric rolling, which induces gradient structural changes hence increasing the density of geometrically necessary dislocations.

The addition of Co to Ni-based alloys can reduce the stacking fault energy. In this study, a novel Ni-26.6Co-18.4Cr-4.1Mo-2.3Al-0.3Ti-5.4Nb alloy was developed by increasing the Co addition to 26.6 wt.%. A new strategy to break the trade-off between strength and ductility is proposed by introducing dense nanosized precipitations, stacking faults, and nanoscale twins in the as-prepared alloys. The typical characteristics of the deformed alloy include dense dislocations tangles, nanotwins, stacking faults, and Lomer–Cottrell locks. In addition to the pinning effect of the bulky δ precipitates to the grain boundaries, the nanosized γ′ particles with a coherent interface with the matrix show significant precipitation strengthening. As a result, the alloy exhibits a superior combination of yield strength of 1093 MPa and ductility of 29%. At 700 °C, the alloy has a high yield strength of 833 MPa and an ultimate tensile strength of 1024 MPa, while retaining a ductility of 6.3%.

The precipitation behavior of Cu-bearing ultra-low carbon steel after step quenching and tempering at 923 K for 0.5–2.5 h was investigated. The size, quantity, and characteristic distribution of nano-precipitates were analyzed using transmission electron microscopy, and the microstructure of B2 (an ordered structure belonging to the body-centered cubic structure), 9R (a special triclinic lattice that has characteristics of rhombohedral structure), 3R (a special triclinic lattice like 9R), and FCT (face-centered tetragonal lattices) were accurately determined. The relationship between nano-precipitates and mechanical properties under different heat treatment processes was obtained, revealing that nano-precipitates effectively enhanced the yield strength of Cu-bearing ultra-low carbon steel. There were two forms of crystal structure evolution sequence of precipitation: B2→multi twin 9R→detwined 9R→FCT→FCC and B2→multi-twin 9R→detwinned 9R→3R→FCT→FCC. The morphology of the precipitated particles during the growth process changed from spherical to ellipsoidal and finally to rod-shaped. It was proven that a stable 3R structure existed due to the coexistence of 9R, 3R, and FCT structures in the same precipitate particle.

In this study, we report a strategy to suppress the formation of large Cu-rich particles by adding excessive interstitial carbon into CuFeMnNi high-entropy alloys. With the increase in C contents in the CuFeMnNi HEAs annealed at 1000 °C, the size and area fraction of the submicron Cu-rich particles markedly decreased. Of note, the CuFeMnNi 1.5 at. %C alloy containing nanosized Cu-rich particles (13 nm) displayed excellent strength–ductility synergy, with yield strength of 695 ± 10 MPa, ultimate tensile strength of 925 ± 20 MPa, and ductility of 21.5%. This is because the addition of carbon significantly increases the diffusion speed of Cu atoms, thereby restraining the growth of Cu-rich nanoparticles. As a result, the comprehensive mechanical properties of the prepared HEAs were significantly enhanced. Additionally, the active diffusion channels induced by high-temperature short-time annealing significantly inhibited the grain growth, which improved the ductility. This work creates a new strategy for solving the dilemma caused by the large Cu-rich particles in the Cu-containing HEAs.

The trade-off between strength and ductility remains a pivotal challenge in the development of multi-principal element alloys (MPEAs) for structural applications. Here, we report a dual-scale ordering strategy to achieve triple strengthening in a Ni-26.6Co-18.4Cr-5.4Nb-4.1Mo-2.3Al-0.3Ti-0.05Y (wt.%) MPEA through the synergistic interplay of L1₂ nanoprecipitates and local chemical order (LCO). The alloy was processed via cold rolling followed by aging at 750 °C for 8 h, resulting in a high density of coherent L1₂ precipitates (average size 47 ± 1 nm, volume fraction ~27%) with an ultra-low lattice misfit of 0.5%. Additionally, sub-nanoscale LCO domains with an average diameter of 0.62 nm were identified within the face-centered cubic matrix. This hierarchical microstructure yields an exceptional combination of mechanical properties at room temperature: yield strength of 1480 ± 6 MPa, ultimate tensile strength of 1678 ± 10 MPa, and a total elongation of 13.9 ± 0.2%. Quantitative strengthening analysis reveals that precipitation strengthening (697 MPa) is the dominant contributor, followed by dislocation strengthening (397 MPa). Transmission electron microscopy characterization of deformed samples reveals that the low stacking fault energy, promoted by LCO, facilitates the dissociation of perfect dislocations and the formation of extensive stacking faults. The intersection of stacking faults on different {111} planes generates a large number of Lomer–Cottrell locks, which significantly enhance work hardening and delay plastic instability. The findings demonstrate that engineering dual-scale ordered structures offers a promising pathway for developing MPEAs with a superior strength-ductility combination.