Evolution of bimodal-structure and achieving ultra-high yield strength in the as-extruded ZK70 alloy via Gd addition

Achieving ultra-high tensile yield strength over 400 MPa in RE modified Mg–Zn-based alloys using conventional thermomechanical processing is a challenging task. In this study, we successfully produced a Mg–7Zn–2Gd–0.5Zr (wt. %) alloy with exceptional strength through traditional hot-extrusion techniques. This alloy exhibits a tensile yield strength of 440 MPa and an acceptable ductility of 4.5%, surpassing a majority of previously reported Mg–Zn-RE-based alloys. Our findings demonstrate that the addition of Gd in Mg–Zn-based alloys effectively retards dynamic recrystallization (DRX) during extrusion, leading to the formation of a distinctive bimodal structure comprising approximately 13.8% coarse un-recrystallized (unDRXed) grains and about 86.2% fine DRXed grains. Furthermore, the alloying effect of Gd enhances particle density, including micron-sized particles and dynamic nano-precipitates. These dynamic precipitates play a crucial role in impeding dislocation movement during extrusion, thereby contributing to the formation of bimodal structure. Additionally, both nano-precipitates and segregation of Zn and Gd atoms towards grain boundaries facilitate the formation of fine DRXed grains through pinning effect. Consequently, the significantly increased tensile yield strength observed in our Gd-modified alloy can be attributed to multiple strengthening mechanisms: fine DRXed grains, strong texture exhibited by unDRXed grains, numerous dynamic precipitates, high-density residual dislocations, and co-segregation of solutes. However, the formation of bimodal structure worsens the yield asymmetry of the Gd-modified alloy due to its strong basal texture. These results provide a valuable insight for further development efforts aimed at achieving ultra-high-strength Mg–Zn-RE-based alloys.