Cluster‐Mediated Solute Stabilization and Shear‐Bypass Synergistic Strengthening in High‐Alloyed Systems

ABSTRACT High alloy content and multiphase synergistic strengthening have become crucial strategies in contemporary metallic materials design for performance enhancement. A major challenge in this field lies in addressing compositional segregation arising from differences in solute diffusion, especially‌ in high‐alloy systems such as aluminum‐lithium (Al‐Li) alloys. This study explores the 2060 Al‐Li alloy, a representative high‐alloy system, produced using twin‐roll casting, a segregation‐sensitive process, and analyzes segregation behavior through a customized solute field model. The results reveal that nanoclusters with high solute tolerance effectively reduce segregation‐induced degradation, leading to significant improvements in both strength and ductility, with an 18.7% increase in strength and a 41.5% increase in elongation. Furthermore, a shear‐bypass synergistic strengthening mechanism was identified. This work not only unlocks the potential of the twin‐roll casting process by leveraging sub‐rapid solidification advantages but also offers a promising technical and theoretical approach to mitigating compositional segregation, addressing a long‐standing challenge within the high‐alloy metallic materials industry.