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Grain refinement via severe plastic deformation (SPD) can induce the decomposition of Al–Zn supersaturated solid solution, resulting in strain softening rather than hardening. So far, it is very challenging to improve the strength of binary Al–Zn alloy by refining grains through SPD. Herein, a single-phase supersaturated solid solution nanostructure with relaxed grain boundaries has been successfully generated in Al–21.7 at% Zn alloy by cryogenic high-pressure torsion. Instead of softening, giant hardening is achieved. The nanocrystalline Al–Zn alloy with grain size of 15 nm has an ultrahigh yield strength of about 642 MPa.

Giant hardening and formation of nanograined supersaturated solid solution in Al–Zn system