In Situ Network-like Bimodal Structure for Superior Strength-Ductility Synergy in WE43 Magnesium Alloy Fabricated via Powder Metallurgy

A rare-earth (RE)-segregation-assisted route combining mechanical alloying and hot extrusion was used to produce a WE43 alloy with an in situ network-like bimodal structure. Mechanical alloying fragmented and partially dissolved RE-containing phases produced a supersaturated Mg-RE solid solution, and dispersed oxygen-bearing surface films. During the pre-sintering stage before hot extrusion, defect-rich prior powder-particle boundaries (PPBs) acted as preferential sinks for RE solutes, establishing RE-enriched regions before extrusion, while some oxygen-bearing species remained near PPBs and grain boundaries. During subsequent hot extrusion, RE solute drag and pinning by RE-containing precipitates and retained oxides restricted grain-boundary migration near PPBs, whereas rotation-assisted grain coalescence and growth occurred within particle interiors. In the 350—extruded alloy, the relatively coarse and fine grains averaged 299 and 144 nm and occupied 71 and 29 vol.%, while the precipitates averaged 97.1 and 9.2 nm. The 400—extruded alloy achieved a yield strength of 396 MPa, an ultimate tensile strength of 432 MPa, and an elongation of 7.9%. For the 350—extruded alloy, Orowan-type, solid-solution, grain-boundary, and dislocation strengthening contributed approximately 118.5, 116.8, 84, and 67 MPa, respectively, leaving an unresolved residual difference of 63.7 MPa. Coupled RE redistribution and oxide dispersion therefore provide a route to a favorable strength–ductility balance in powder-metallurgy Mg alloys.