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Developing ultra-high strength in rare-earth-free Mg alloys using conventional extrusion process is a great challenge. What is even more difficult is to achieve such a goal at a lower processing cost. In this work, we report a novel low-alloyed Mg-2Sn-2Ca alloy (in wt. %) that exhibits tunable ultra-high tensile yield strength (360–440 MPa) depending on extrusion parameters. More importantly, there is little drop in mechanical properties of this alloy even when it is extruded at a speed several times higher than those used in the reported high strength Mg alloys. Examination of as-extruded microstructures of this Ca-containing Mg alloy reveals that the ultra-high strength is mainly associated with the presence of surprisingly submicron matrix grains (down to ∼0.32 μm). The results suggest that the Ca addition promotes accumulations of the pyramidal dislocations, which eventually transform into the low angular grain …