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An ultra-high strength and low-cost magnesium wrought alloy, Mg-1Ca-1Al-0.3Zn-0.4Mn (wt%), has been fabricated by conventional extrusion, with yield strength of ~435 MPa, the ultimate tensile strength of ~449 MPa and the elongation of ~4.2%. Mono-dispersive nano-precipitations, e.g., the Al 2 Ca phase and AlMn phase, have been induced during extrusion, which can effectively pin pyramidal dislocation motions in grain interiors and thus provide substantial nucleation sites for dynamic recrystallization in present Ca-containing Mg alloys. Simultaneously, these fine-precipitates distributing at the new grain boundaries can prevent their growths, which thus guarantee the ultra-fine grains formation (300–500 nm). After heat treatment, a higher number density of nano Al 2 Ca and AlMn phases can be further precipitated, which results in the alloy still maintaining the ultra-high strength of ~444 MPa. The multiple roles of the same nano-precipitations in both promoting the ultrafine grains formation and affording precipitation hardening have been clarified in present Mg wrought alloy. • Ultra-high strength of ~449 MPa was achieved in the low-cost Mg-1Ca-1Al-0.3Zn-0.4Mn (wt%) wrought alloy. • Ultra-fine grain size (300–500 nm) was achieved due to ther fine-precipitates distributing at the new grain boundaries. • A higher number density of nano-precipitations could afford extra precipitation hardening effect after heat treatment. [ABSTRACT FROM AUTHOR]

In this work, the role of Al addition in modifying the microstructure and mechanical properties of the Mg-1.0Ca- x Al (x = 0.6, 1.0 wt%; termed as XA10 and XA11, respectively) based alloys has been systematically investigated. Microstructural examination showed that, when the Al content is low, the Al and Ca atoms were inclined to segregate to the dislocation lines in the XA10 sample. As a result, the mobility of dislocation was restrained and the dynamic recovery behavior was hindered, which leads to a low degree of dynamic recrystallization. When the Al content is high, in contrast, no apparent Ca/Al segregations along dislocations have been found in XA11-0 extrusion billet during the whole stages of processing, which results in the enhanced dislocation mobility. Consequently, the recovery of dislocations and dynamic recrystallization rate can be largely enhanced at the earlier stage of extrusion. More importantly, subsequently formed high density Guinier-Preston (G.P.) zones and nano-disk Al 2 Ca phases in the high-Al content Mg sample can play an effective role in inhibiting the growth of subgrains and dynamically recrystallized (DRXed) grains, which enhance the thermal stability of high density low angular grain boundaries (LAGBs) in the later extrusion stage. The high density nano-disk phases, high volume fraction of DRXed grains, as well as the high density LAGBs in the un-DRXed grains, can together contribute to both high strength and good elongation of the XA11 sample. The findings lead to the controllable Mg-Ca based alloy designing strategy that can improve the strength and ductility simultaneously. • An excellent strength-ductility synergy was achieved at dilute alloying content. • The dynamic recrystallization behavior of the low-alloyed Mg-Ca-Al based alloy was investigated. • The segregation of Ca/Al atoms to dislocations take place preferentially at lower Al content. • The high density nano-disk phases, DRXed grains, as well as the LAGBs in the un-DRXed grains were observed in higher Al content. [ABSTRACT FROM AUTHOR]