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Acta Metall Sin  2025, Vol. 61 Issue (11): 1593-1602    DOI: 10.11900/0412.1961.2025.00234
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Hierarchical Lamellar Heterostructure Design Renders Metallic Materials with Ultrahigh Strength-Ductility Combinations
ZHONG Yunbo(), SHI Peijian()
State Key Laboratory of Materials for Advanced Nuclear Energy, School of Materials Science and Engineering, Shanghai University, Shanghai 200444, China
Cite this article: 

ZHONG Yunbo, SHI Peijian. Hierarchical Lamellar Heterostructure Design Renders Metallic Materials with Ultrahigh Strength-Ductility Combinations. Acta Metall Sin, 2025, 61(11): 1593-1602.

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Abstract  

“Heterogeneous structures” or “heterostructures” have emerged as a cutting-edge paradigm in the field of mechanical strengthening and toughening, promising to overcome the long-standing trade-offs among strength, ductility, and toughness in metallic materials. Inspired by the multiscale design principle of natural materials, researchers have proposed a synergistic design of bioinspired “hierarchical lamellar heterostructures”, enabling exceptional and simultaneous enhancements in the strength, ductility, and toughness of metallic materials. This study reviews the theoretical foundations, design principles, and strengthening-toughening mechanisms underpinning several archetypal hierarchical lamellar heterostructures: bionic herringbone type, micro-lamellar heredity pattern, and cocoon-like dislocation network model. This review focuses on how these hierarchical lamellar heterostructures effectively overcome the strength-ductility trade-off limitations imposed by uncontrolled crack propagation, ultrafine grain structures, and high-density dislocations. It also elucidates how this heterostructure strategy and its remarkable efficacy have been successfully extended to multiple metal systems, enabling the design and fabrication of a new generation of key high-speed railway contact wires with internationally leading comprehensive performance. Finally, the review discusses the prospects for developing more advanced hierarchical lamellar heterostructured materials and explores their potential future directions.

Key words:  heterogeneous structure      strengthening and toughening      bioinspired      hierarchical lame-llar heterostructure      strength-ductility trade-off     
Received:  13 August 2025     
ZTFLH:  TG142  
Fund: National Natural Science Foundation of China(U23A20607);National Key Research and Development Program of China(2022YFC2904900)

URL: 

https://www.ams.org.cn/EN/10.11900/0412.1961.2025.00234     OR     https://www.ams.org.cn/EN/Y2025/V61/I11/1593

Fig.1  Bioinspired herringbone-patterned hierarchical duplex lamellar hetrostructure achieving superior crack resistance and mechanical properties
(a) schematics of the high-temperature gradient directional solidification equipment and the evolution of solid-liquid interface (EHEA—eutectic high-entropy alloy)
(b) SEM images and schematics of herringbone and crystal structures[24] (Black arrow marks the solidification direction)
(c) SEM images[24] (Insets (upper, enlarged; lower, schematic) illustrate dynamic microcrack evolution)
(d) comparison diagram of strength and ductility[24]
Fig.2  Hierarchical lamellar heterostructure engineered by inheriting microstructural lamellae and multi-stage strain hardening induced by multiple types of nano-twins
(a) microstructure evolution of as-cast, rolled, and annealed states[6] (RD—rolling direction, TD—transverse direction)
(b) tensile stress-strain curves[6] (Inset shows the loading-unloading-reloading curves)
(c) STEM image[6] (The dual-phase lamellae and the intergranular B2 grains (P2) (indicated by yellow dashed lines and red arrows, respectively) show apparent dislocations. The dashed blue arrows point out different deformation directions, and even some fcc grains deform along two directions)
(d) SEM image showing the multiple microcracks mainly including circle-like, tortuous, and even submicron cracks (indicated by red, blue, and yellow arrows, respectively)[6]
(e) SEM image showing significantly-increased dislocations in fcc grains around P2 (The piling-up of geometrically necessary dislocations is marked by dashed red lines)[6]
(f) multistage strain-hardening curves[23] (HDI—hetero-deformation induced, d—grain size, b1-b3—three different partial dislocations, τ—shear stress, PB1 and PB2—two phase boundaries)
Fig.3  Hierarchical lamellar heterostructure reinforced by cocoon-like super-nano dislocation network, which induces strong dislocation planar slip and superior mechanical properties[26]
(a) STEM images
(b) three-dimensional atom probe tomography (3D-APT) images
(c) tensile curves and comparison diagram of strength and ductility (Inset shows corresponding strain-hardening curves)
(d) schematic of strong dislocation planar slip and high-angle annular dark-field (HAADF) STEM images (Pink and yellow arrows mark dislocations with multi-directional planar slip and dislocations with slip transmission, respe-ctively)
Fig.4  Bioinspired, heredity-derived hierarchical fibrous lamellar (HFL) structured copper alloys with superior properties[25]
(a) schematic of continuous extrusion and rotary swaging processes for continuous casting copper alloy bars
(b) schematic of HFL heterostructure
(c) comparison diagram of yield strength, uniform elongation versus conductivity
(d) radar chart of multiple property values or trends of ultrafine-grained (UFG) and HFL samples
(e) broad application prospects (Inset shows as-fabricated CuCrZr bar)
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