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Residual stress exists extensively in biological and engineering structures. Here we report that residual stress can be engineered to significantly enhance the strength and ductility of gradient materials. In-situ synchrotron experiments revealed that the strongest strain hardening occurred in the layer with the highest compressive residual stress in a gradient structure. This layer remained elastic longer than adjacent layers during tension, producing high hetero-deformation induced stress to increase strength and enhancing work hardening even after the disappearance of the compressive stress to increase ductility. This finding provides a new paradigm for designing gradient structures for superior mechanical properties.

Abstract High-carbon martensite steels (with C > 0.5 wt.%) are very hard but at the same time as brittle as glass in as-quenched or low-temperature-tempered state. Such extreme brittleness, originating from a twin microstructure, has rendered these steels almost useless in martensite state. Therefore, for more than a century it has been a common knowledge that high-carbon martensitic steels are intrinsically brittle and thus are not expected to find any application in harsh loading conditions. Here we report that these brittle steels can be transformed into super-strong ones exhibiting a combination of ultrahigh strength and significant toughness, through a simple grain-refinement treatment, which refines the grain size to ~4 μm. As a result, an ultra-high tensile strength of 2.4~2.6 GPa, a significant elongation of 4~10% and a good fracture toughness (K1C) of 23.5~29.6 MPa m1/2 were obtained in high-carbon martensitic steels with 0.61–0.65 wt.% C. These properties are comparable with those of “the king of super-high-strength steels”—maraging steels, but achieved at merely 1/30~1/50 of the price. The drastic enhancement in mechanical properties is found to arise from a transition from the conventional twin microstructure to a dislocation one by grain refinement. Our finding may provide a new route to manufacturing super-strong steels in a simple and economic way.