Micro-/nano-scale interface structure and mechanical characteristics of the Al/Ti composite bar produced by a novel continuously-extruded technique

•The Al/Ti composite bar obtained by a novel continuously-extruded technique exhibits a superior strength-ductility balance.•A nanocrystalline Al layer is generated at the interface, accompanying with the precipitation of Mg-/Si-enriched clusters.•Nanoscale TiAl3 grains are nucleated on the Ti/TiAl3 interface, inducing the formation of misfit dislocations.•The dislocation-interface interaction and constraint effect are triggered on the 3D interface during deformation.