Unveiling superior ductility in refractory high entropy alloy through preexisting {112}<111> twins and novel rotational twinning dynamics

The synergistic enhancement of strength and ductility remains an urgently demanded challenge for refractory high entropy alloys (RHEAs). Here, we propose a novel preexisting twinning strategy to achieve excellent strength-ductility synergy. Advanced crystallographic analysis and molecular dynamics simulations reveal that the mechanism of preexisting {112}<111> twinning enhances the ductility via inducing rotational twinning. The rotational twins serve as an effective slip transfer interface and dislocation reaction node, which facilitates the local strain coordination. More crucially, the following rotational twin modes have been identified: {11¯4}<221‾>, {11¯5}<552‾>, {11¯7}<772‾>, {11¯9}<992‾> (rotation around the common <110> pole), and a special {21‾1}<111> mode, in stark contrast to the classical twinning shear mechanism. At 723-823 K, preexisting twins trigger early dynamic recrystallization, refine grain structures, and serve as nucleation sites for deformation twins, while atomic kinks along the rotational twin boundaries dynamically drive twin rotation and suppress crack propagation. Consequently, the non-equiatomic TiNbZrHfTa alloy reaches a remarkable yield strength of ∼660±11 MPa with 20.74±1.26% elongation at 723 K, and elongations exceeding 17% at 823 K and 50% at 923 K, respectively, which successfully overcomes the intermediate-to-high-temperature embrittlement problem of RHEAs. Altogether, this work offers a transformative pathway for designing high-performance RHEAs for extreme environments.