Strength–Ductility Synergy and Microscopic Mechanism of CNTs-Reinforced Mg-Al Composites Fabricated Through Vacuum Powder Metallurgy Coupled with Hot Extrusion–Rolling

The low absolute strength and insufficient room-temperature ductility remain key bottlenecks that restrict the engineering application of magnesium alloys in high-end industrial fields. In the present study, 1 vol.% carbon nanotubes (CNTs)-reinforced Mg-xAl (x = 0, 1, and 1.5 wt.%) composites were synthesized via a powder metallurgy route coupled with hot extrusion–rolling processing to realize a simultaneous improvement in mechanical properties. The hot extrusion–rolling processed 1 vol.% CNTs/Mg-1Al composite exhibits an ultimate tensile strength of 300 MPa and an elongation to failure of 9%, showing an excellent strength–ductility synergy. Microstructural characterization reveals a well-bonded interface between CNTs and the Mg matrix. Deformation incompatibility between CNTs and the magnesium matrix during hot extrusion–rolling induces a high density of dislocations, providing an important strengthening contribution. Moreover, an increased proportion of low-angle grain boundaries and the development of a bimodal texture promote significant grain refinement and effectively activate non-basal slip systems, thereby alleviating plastic deformation constraints. The synergistic effects of interfacial strengthening, dislocation strengthening, grain boundary strengthening, and texture regulation together contribute to the simultaneous improvement of strength and ductility in CNTs-reinforced Mg-Al composites.