Performance optimization and deformation mechanisms of multiscale heterostructured metals: A review

Abstract

The performance demands for metals are continuously increasing. Introducing heterostructures into metals to overcome the conventional strength-ductility trade-off has garnered significant attention in recent years as a new material design paradigm. This review delineating representative heterostructure systems—including laminated, bimodal/multimodal, gradient, core-shell, and dual-phase structures—and systematically details their corresponding fabrication techniques. Subsequently, the focus shifts to evaluating the mechanical property enhancements imparted by various heterostructures across diverse metallic systems. It discusses the core deformation mechanisms, including hetero deformation induced (HDI) stress and strain hardening, the role of plastic strain gradients and geometrically necessary dislocations (GNDs), the interaction between dislocations and hetero-interfaces, and the evolution and suppression of shear banding. Finally, it addresses the problems and challenges, such as scalable manufacturing and interfacial stability. It also looks forward to future development directions for the design and practical applications of these advanced materials. This review endeavors to serve as a comprehensive roadmap, bridging fundamental research with the widespread industrial application of heterostructured metals.

Keywords

heterostructured metals / strength-ductility synergy / gradient structures / heterogeneous deformation-induced (HDI) stress / geometrically necessary dislocations (GNDs)

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