Ultra-strong heavy-drawn eutectic high entropy alloy wire

Metallic wires with high strength-ductility at both room and cryogenic temperatures are always pursued for engineering applications. However, traditional metallic wires are tortured inevitably by strength-ductility trade-off dilemma. In this work, a gradient heterogeneous lamella structure, characterized with hard gradient-distributed B2 lamellae embedded in soft FCC lamellae matrix, is introduced into AlCoCrFeNi2.1 eutectic high entropy alloy (EHEA) wire by well-designed multiple-stage heavy-drawn and heat treatment processes, which achieves an outstanding strength-ductility synergy. This EHEA wire exhibits not only high tensile strength of 1.85 GPa and sufficient uniform elongation of ∼12% at room temperature, but also ultra-high tensile strength of 2.52 GPa and even slightly elevated uniform elongation of ∼14% at cryogenic temperature. In-depth microstructure characterization indicates that the gradient heterogeneous lamella structure facilitates a radial gradient distribution of geometrically necessary dislocation (GND) during tension, i.e., the GND density decreases gradually from the surface region to the central region of EHEA wire, which induces pronounced strain gradient strengthening effect and thus greatly benefits the mechanical properties. Intriguingly, at cryogenic temperature, dense cross-slip which gives rise to intensively dynamic microstructure refinement is firstly observed in the B2 phase of EHEA wire. The activation of cross-slip provides sufficient ductility while inducing evidently dynamic Hall-Petch effect, becoming the most effective deformation mechanism contributing to the unprecedented cryogenic tension properties. This work sheds light on designing ultra-strong EHEA wire and other advanced metallic wires.