Approaching 1 GPa Ultra‐High Tensile Strength in a Nanostructured Al–Zn–Mg–Cu–Zr–Sc Alloy Prepared by Severe Plastic Deformation

Alloy composition and heat treatment processes have limited possibility to enhance ultra‐high strength of aluminum alloys, which restricts their widespread application in lightweight equipment. Consequently, high‐density dislocations and grain refinement are suggested to strengthen ultra‐high strength aluminum alloys. Herein, a novel nanostructured Al–Zn–Mg–Cu–Zr–Sc (AZMCZS) alloy with homogeneous microstructure is prepared through the synergistic processing of hot extrusion and high‐pressure torsion. Additionally, the microstructures and strengthening mechanisms of the nanostructured Al alloy are analyzed. It is observed that the ultimate tensile strength of the nanostructured Al alloy reaches nearly 1 GPa, and the elongation of the alloy is 1.9%. The nanostructured Al alloy mainly consists of nanoscale grains (≈117.7 nm), high‐density dislocations (2.4 × 10 15 m −2 ), nano‐sized precipitates (the size of 20–51 nm), and solute atom clusters (≈3 nm). The multiple strengthening mechanisms of the nanostructured Al alloy are revealed in terms of grain refinement, dislocations, precipitates, and solute atom clusters. Grain refinement and dislocation strengthening show superior outcomes and are considered to be the predominant strengthening mechanisms. These findings demonstrate that this nanostructural architecture offers a new way to design super‐strength metals and alloys by effectively controlling the processing regime of severe plastic deformation.