Designing ultrastrong and thermally stable FeCrAl alloys with the fine-grained structure

Designing microstructurally stable FeCrAl alloys with excellent strength-ductility synergy is highly desirable for their engineering applications. However, due to the preference nucleation of precipitates at grain boundaries (GBs), the improved precipitation strengthening of these alloys is usually accompanied by intergranular embrittlement. Here, we propose a novel thermomechanical processing route coupled with the Si alloying strategy via precipitation of coherent deformable Laves precipitates inside equiaxed fine-grains to achieve FeCrAl alloys with ultrahigh yield strength over ∼992 MPa, excellent uniform elongation of ∼7.6% at room temperature, and superior thermal stability at temperature ∼1200 °C. The Si alloying not only decreases the stacking fault energy of Laves precipitates favorable for their stacking-fault-mediated deformation but also hinders grain coarsening at 1200 °C due to the Si-enrichment favorable for GB pinning effects. Our results prove the possibility of achieving the collaborative enhancement of mutually exclusive properties in alloys, such as strength-ductility-thermal stability via nanoprecipitation engineering, and offer a promising route to prepare dispersion-strengthened materials.