Ultra-fine-grained and gradient FeCrAl alloys with outstanding work hardening capability

FeCrAl alloy is a promising accident tolerant fuel cladding material for next generation nuclear reactors. Grain refinement may lead to FeCrAl alloys with improved mechanical properties. However, the addition of Al retains the ferrite phase and makes the grain refinement difficult through conventional thermomechanical treatments. In this study, a model FeCrAl alloy, C35M, was processed by surface mechanical grinding treatment. Microscopy studies show the formation of gradient microstructures, consisting of surface nanolaminate layer and ultra-fine-grained sublayer. In situ micropillar compression tests reveal the gradient FeCrAl alloy has a high flow stress, exceeding 1.4 GPa, and excellent work hardening capability. A modified Kocks-Mecking model was utilized to explain the grain size-dependent work hardening behavior. This study sheds lights on the design of gradient ferritic steels with high-strength and good work hardening ability for various industrial applications.