Synthesis of a bulk nanostructured metastable Al alloy with extreme supersaturation of Mg

Nanostructuring of bulk metals is now well documented with the development of severe plastic deformation (SPD) for improving the physical and mechanical properties of engineering materials. Processing by high-pressure torsion (HPT), which was developed initially as a grain refinement technique, was extended recently to the mechanical bonding of dissimilar metals during nanostrcturing which generally involves significant microstructural heterogeneity. Here we introduce, for the first time, a bulk metastable Al-Mg supersaturated solid solution by the diffusion bonding of separate Al and Mg metal solids at room temperature using HPT. Exceptional hardness was achieved homogeneously throughout the metastable alloy with a record maximum supersaturated Mg content of ~38.5 at.% in the Al matrix having a grain size of ~35–40 nm. Our results demonstrate the synthesis of a bulk nanocrystalline metastable alloy with good microstructural stability at room temperature where such bulk solids are not yet reported for mechanical alloying by powder metallurgy.