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The method of radial shear rolling makes it possible to achieve comparable to high pressure torsion (HPT) method ultrahigh degrees of total strain level in combination with the vortex metal flow character for long-length large bulk bars unable by HPT and many other processes of sever plastic deformation (SPD). Sequential rolling of the Zr-1%Nb alloy was carried out under extreme conditions on two radial shear rolling mills with a total diameter reduction ε = 185% and a maximum total strain level = 46 mm/mm. The strain level and its cross-section distribution assessment by finite element method (FEM) simulation was studied. The final bar cross-section structure type distribution detailed study 1 mm resolution by electron back scatter diffraction (EBSD) mapping was performed. A gradient structure with a predominance of the equiaxed ultrafine-grained (UFG) state was found. The deformation level rising did not allow to refine it in the periphery zone more than that obtained nearly middle of the processing, but it allows for significant change in the axial zone structure. The additional large warm deformations by radial shear rolling have no additional grain refinement effect for already 300–600 nm refined zone. An equiaxed UFG structure was obtained in a relatively large volume of the sample with a reduced gradient towards the non-UFG center zone in regard to known works.

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