The limitation of nanograined materials is their strong tendency to coarsen at elevated temperatures. As grain size decreases into the nanoscale, grain coarsening occurs at much lower temperatures, as low as ambient temperatures for some metals. We discovered that nanometer-sized grains in pure copper and nickel produced from plastic deformation at low temperatures exhibit notable thermal stability below a critical grain size. The instability temperature rises substantially at smaller grain sizes, and the nanograins remain stable even above the recrystallization temperatures of coarse grains. The inherent thermal stability of nanograins originates from an autonomous grain boundary evolution to low-energy states due to activation of partial dislocations in plastic deformation.

Metals usually exist in the form of polycrystalline solids, which are thermodynamically unstable because of the presence of disordered grain boundaries. Grain boundaries tend to be eliminated through coarsening when heated or by transforming into metastable amorphous states when the grains are small enough. Through experiments and molecular dynamics simulations, we discovered a different type of metastable state for extremely fine-grained polycrystalline pure copper. After we reduced grain sizes to a few nanometers with straining, the grain boundaries in the polycrystals evolved into three-dimensional minimal-interface structures constrained by twin boundary networks. This polycrystalline structure that underlies what we call a Schwarz crystal is stable against grain coarsening, even when close to the equilibrium melting point. The polycrystalline samples also exhibit a strength in the vicinity of the theoretical value.

Dislocations in crystals naturally break the symmetry of the bulk, introducing local atomic configurations with symmetries such as fivefold rings. But dislocations do not usually nucleate aperiodic structure along their length. Here we demonstrate the formation of extended binary quasicrystalline precipitates with Penrose-like random-tiling structures, beginning with chemical ordering within the pentagonal structure at cores of prismatic dislocations in Mg–Zn alloys. Atomic resolution observations indicate that icosahedral chains centered along [0001] pillars of Zn interstitial atoms are formed templated by the fivefold rings at dislocation cores. They subsequently form columns of rhombic and elongated hexagonal tiles parallel to the dislocation lines. Quasicrystalline precipitates are formed by random tiling of these rhombic and hexagonal tiles. Such precipitation may impact dislocation glide and alloy strength.