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Oxide dispersion strengthened FeCrAl alloys dispersed high-densitynano-oxides in the matrix show outstanding corrosion resistance and mechanicalproperties. However, ODS FeCrAl alloys achieve the high strength generally atthe expense of ductility in some way. Here, a method by introducing a bimodalgrain structure was designed to overcome the strength-ductility tradeoff. Inthis work, ODS FeCrAl alloys were successfully fabricated through variousmechanical alloying time, combined with spark plasma sintering under the vacuumof less than 4Pa. Microstructural characterization showed that the averagegrains size and nano-oxides size decrease gradually, and the density ofnano-oxides increases, as the milling time increases. Mechanical propertiesrevealed that both the strength and ductility were significantly synergisticenhanced with increasing milling time. The bimodal grain distributioncharacterized by electron backscatter diffraction (EBSD) (vacuum degree wasless than 5E-5pa) was beneficial for the activation of the back stressstrengthening and the annihilation of these microcracks, thus achieving theexcellent ductility (27.65%). In addition, transmission electron microscope(TEM) characterization under the vacuum degree of less than 10-6pa illustratedthat ultra-high-density nano-oxides (9.61E22/m3) was crucial for enhancing thestrength of ODS FeCrAl alloys (993MPa). The strengthening mechanismsuperposition, based on the model of nano-oxides interrelated with thedislocation, illustrated an excellent agreement with experimental results fromyield strength strengthening mechanisms. To our best knowledge, H40 (milled for40h, and sintered at 1100C) alloy presents the outstanding strength with theexceptional ductility among all studied ODS FeCrAl alloys, which makes it thepromising cladding materials for the accident tolerant fuel cladding.

Enhanced strength-ductility combination by introducing bimodal grains  structures in high-density oxide dispersion strengthened FeCrAl alloys  fabricated by spark plasma sintering technology