Superior strength–ductility synergy in three-dimensional heterogeneous-nanostructured metals

Heterogeneous microstructural design has been proven to be an effective strategy in breaking the strength–ductility dilemma in nanostructured metals. However, the precise control of heterogeneous microstructures to achieve strength–ductility synergy remains challenging. Here, we demonstrate a novel powder metallurgy approach for creating three-dimensional (3D) core–shell nanostructures with highly tunable shell thickness and grain size distributions. These 3D nanostructures enable superior strength–ductility synergy in pure copper, pushing the boundary of the Ashby map to unchartered territory. A combination of microstructural characterization, atomistic simulations and crystal plasticity modeling reveals that the generation and accumulation of geometrically necessary dislocations near the core–shell interface play a pivotal role in accommodating the strain gradient and sustaining a high strain-hardening rate during plastic deformation. Our work provides a viable approach for designing bulk nanostructured materials with 3D heterogeneous ingredients and demonstrates a promising pathway for the development of strong and ductile materials.