Mechanistic investigation of a low-alloy Mg–Ca-based extrusion alloy with high strength–ductility synergy

High strength–ductility synergy is difficult to achieve in Mg alloys. Although high strength has been achieved through considerable alloying addition and low-temperature extrusion, these techniques result in low ductility (2%–5%). In this work, a novel low-alloy Mg–Ca-based alloy that overcomes this strength–ductility trade-off is designed. The alloy has an excellent tensile yield strength (∼425 MPa) and exhibits a reasonably high elongation capacity (∼11%). A microstructure examination reveals that a high density of submicron grains and nano-precipitates provides the alloy high strength, and the leaner alloy additions and higher extrusion temperatures initially improve ductility. As a result, the density of residual dislocations is reduced, and the formation of low-angle grain boundaries (LAGBs) is enhanced. With fewer residue dislocations, it becomes less probable for the newly activated mobile dislocations to be impeded and transformed into an immobile type during the subsequent tensile test. The LAGBs function as potential sites to emit new dislocations, thus enhancing the dislocation–multiplication capability. More importantly, they can induce evident sub-grain refinement hardening and guarantee that the alloy achieves high strength. The findings lead to a controllable Mg alloy design strategy that can simultaneously afford high strength and ductility.