Hyper-Range Amorphization Unlocks Superior Damage Tolerance in Alloys

Shear bands dictate the failure mechanisms of alloys across various strain rates and limit the damage tolerance of the alloy. While short-range amorphization has the potential to mitigate shear effects, it has thus far been confined to the nanoscale. Here, we extend amorphization to the micrometer scale, fundamentally replacing shear-dominated failure in multi-principal element alloy micropillars. We implement continuous compression strain-training from low to high strain rates, generating a top-down high-density dislocation gradient that drives the formation of a topological disorder network, extending over one-third of the micropillar height, which we define as hyper-range amorphization. Within the amorphous bands, atoms exhibit dynamic disorder, and the lattice rearranges and recovers, dissipating shear stress. The alloy achieves an ultimate compressive strength of ceramic level ( ~ 6.5 GPa), while maintaining ~59.1% plasticity. This work reveals a strain engineering-based mechanical mechanism for extending amorphization, establishing it as a viable pathway to enhancing the structural stability and energy dissipation capacity of alloys.