Powder metallurgy (PM) Ti alloys, produced by compacting blended powders followed by vacuum sintering, offer reduced production costs compared to casting−wrought Ti alloys. However, the conventional pressureless sintering recipe usually incorporates high temperature and long holding time, inevitably leading to oxygen pick-up and grain coarsening, which markedly decreases their plasticity. In recent years, novel rapid sintering techniques, i.e., induction sintering, microwave sintering, spark plasma sintering, hot pressing, and hot isostatic pressing, could achieve densification of powders in several minutes, which is beneficial to the control of oxygen content increase and grain  growth. In this work, we review these advanced sintering methods and the emphasis is on exploring microstructural evolution and densification mechanisms using pure Ti and TC4 alloys as examples. Besides, limitations of each sintering approach are summarized, and their application potentials are evaluated as well. At the end, development directions of advanced rapid sintering techniques are outlined.

The precipitation behavior of Al−xCu−yLi−Z alloys (Z=0.4Ag−0.4Mg−0.5Zn−0.3Mn−0.1Zr, in wt.%) was regulated by optimizing the Cu/Li mass ratio (2.5, 3.2, and 3.7). For the as-extruded alloys, the area fraction of fine secondary phases (f_s-d<1 μm) increases to 9.1% with Cu/Li mass ratio of 3.2, then decreases to 7.8% with a further increase of Cu/Li mass ratio. The Al−4.1Cu−1.3Li−Z alloy (CL2) exhibits the highest f_s-d<1 μm and dislocation density. The precipitation sequence of the CL2 follows: SSSS → GP zone → GP zone + δ' + θ' + T₁ → δ' + θ' + T₁. In the peak-aged condition, CL2 contains T₁ precipitates with the largest diameter of 162 nm and highest volume fraction of 2.1%. Consequently, CL2 achieves superior mechanical properties with yield strength of 694 MPa, ultimate tensile strength of 739 MPa, and elongation of 5.9%, which can be attributed to its highest Cu and Li contents and strongest precipitation driving force.

To elucidate the influence mechanism of microstructures on the wrinkling behavior during sheet plastic forming, the effects of different processes (heat treatment, repetitive rolling and straightening (RRS)) on the microstructures and mechanical properties of 6061 aluminum alloy sheets were systematically investigated by employing shear wrinkling tests and numerical simulation methods. Furthermore, the relationship between both microstructures and mechanical properties and the sheet wrinkle resistance was explored. The results show that decreasing average grain size, reducing plastic elongation, or increasing yield strength can reduce the equivalent strain at the critical wrinkling moment, thereby diminishing the wrinkle resistance of the materials. Conversely, decreasing either the proportion of low-angle grain boundaries (LAGBs) or material hardness can increase the critical equivalent strain, consequently enhancing wrinkle resistance of the materials. Consequently, the combination of heat treatment with the RRS modification process can improve sheet wrinkle resistance while enhancing comprehensive mechanical properties.

To investigate fracture behavior in 5052-O aluminum alloy tubes during the shear forging process, tensile tests were conducted for four types of specimens including notched specimens, plane strain specimens, specimens with a central hole, and shear specimens. The normalized Cockcroft−Latham, Oyane, and Ayada ductile fracture criteria were then calibrated using a hybrid experimental−numerical approach to determine their critical damage values. A stress analysis was performed at the fracture locations, and a process window influencing fracture behavior was established. Results showed that fracture typically initiated on the sidewall surface of the cylindrical part near the punch corner. Among the criteria, the Ayada model calibrated with shear specimens yielded the highest prediction accuracy (error 5.9%), while the normalized Cockcroft−Latham model calibrated with notched specimens showed the lowest accuracy (error 37.7%). The fracture occurred under a tension-dominated tension-shear deformation mode. Increasing the punch corner radius and counter punch force was found to delay fracture initiation.

The mechanical properties, anisotropy and microstructure of 8011 aluminum alloy foils annealed at different temperatures were studied. The results show that compared with the foils annealed at 300 and 400 °C, the foil annealed at 350 °C has the highest yield strength (63.9 MPa) and the lowest anisotropy, with a high normal anisotropy (=0.625) and a low planar anisotropy (Δr=−0.033). The elevated annealing temperature induces spheroidization of coarse particles and coarsening of fine particles, accompanied by the transformation from deformation texture to recrystallization texture. The foil annealed at 350 °C exhibits better mechanical properties, which is attributed to the synergistic effects of dislocation strengthening, grain refinement, texture strengthening and precipitation strengthening. Furthermore, the particle stimulated nucleation mechanism and uniform distribution of Schmid factors increase random texture, which weakens texture strength and anisotropy of the foil. Therefore, the foil annealed at 350 °C presents the best mechanical properties and the lowest anisotropy.

The pulsed cold metal transfer (CMT+P) welding technology was utilized. Pre-weld aging treatment combined with post-weld aging treatment was employed to regulate the microstructure and mechanical properties of the heat-affected zone (HAZ) in Al−Mg−Si−Cu alloy welded joints. Results indicate that pre-weld aging can enhance the diffusion rate of the solute atoms and promote Guinier−Preston (GP) zones. After welding thermal cycling, the GP zones quickly transform into a coarse equilibrium phase, and some small particles dissolve back into the matrix. Post-weld aging promotes secondary precipitation of precipitates. After (180 °C, 1 h) pre-weld aging + (180 °C, 1 h) post-weld aging treatment, the tensile strength of the HAZ in the joint reaches 319.7 MPa, which is 34.1% higher than that in the T4 state, and the welding coefficient reaches 82.0%.

A novel nacre-like Al/eutectic high-entropy alloy (Al/EHEA) composite was fabricated using selective laser melting coupled with vacuum hot pressing. The effects of different process parameters, such as vacuum hot pressing temperature, on the interface microstructure, element distribution, diffusion thickness, and mechanical properties of the Al/EHEA composite were investigated. The results demonstrated that a robust bonding interface was achieved without the formation of intermetallic compounds, with the maximum diffusion thickness reaching 2.45 μm at 620 °C in the Al/EHEA composite. The composite processed at this temperature exhibited an average grain size of 4.73 μm, effectively enhancing ductility and toughness through the suppression of crack propagation and dislocation motion. The Al/EHEA composite exhibits a compressive strength of 182.2 MPa and an ultimate tensile strength of 280.8 MPa at 620 °C. The EHEA skeleton achieved an ultimate tensile strength of 1699.8 MPa at 620 °C, driven by the synergistic effect of the grain refinement and heterogeneous lamellar structure.

To overcome the trade-off between thermal conductivity and mechanical properties in magnesium alloys, Mg−6Gd−1Er−xZn−0.6Zr (x=0, 1, 3, and 6 wt.%) alloys were developed using T4 + T6 treatment. The results show that increasing Zn content promotes the formation of (Mg,Zn)₃RE and LPSO phases, which reduce RE solutes in the Mg matrix, thus enhancing thermal conductivity of the alloys. Zn and Mg atoms, with smaller differences in atomic radius and valence compared to RE atoms, have a weaker impact on electrons and phonon scattering. Solution treatment lowers thermal conductivity of the alloy, while aging improves it. The peak-aged GEZ616K alloy demonstrated an optimal combination of mechanical properties (UTS of 312 MPa, YS of 201 MPa and EL of 25.4%) and thermal conductivity (136.9 W/(m·K)) due to the precipitation of the nano-scale (Mg,Zn)₅Gd and γʹ phases. This study offers a new strategy for designing Mg alloys with both high strength and thermal conductivity.

Two novel lightweight multicomponent extruded Mg_92−xAl_xZn₄Cu_3.5Ce_0.5 (x=3 and 8, at.%; labeled as A3 and A8 alloys, respectively) alloys were developed to address the low strength, stiffness, and plasticity of magnesium alloys by tailoring the types and concentrations of the secondary phase. The results demonstrate that the as-extruded A3 alloy exhibits an excellent tensile fracture strain of 10.6%, while the as-extruded A8 alloy has higher ultimate tensile strength and yield strength of 300.5 and 230.0 MPa, respectively. In addition, the main secondary phases of the as-extruded A3 alloy are Al₃CuCe, MgZnCu, and MgAl_0.93Cu_1.07 phases, whereas those of the as-extruded A8 alloy predominantly consist of Al₃CuCe and MgAl_0.93Cu_1.07 phases. Notably, the secondary phases in Mg_92−xAl_xZn₄Cu_3.5Ce_0.5 alloys promote the dynamic recrystallization during the extrusion process. Compared to the A8 alloy, the A3 alloy exhibits superior plasticity, which is primarily attributed to the activation of basal and prismatic slip systems during thermal deformation.

The influence of the volume fraction of B₄C nanoparticles (B₄C_np) on the mechanical properties of Mg−B₄C composites was investigated. Mg−xB₄C (x=5 and 7 vol.%) composites were fabricated via low-energy ball milling, spark plasma sintering (SPS), and hot extrusion. The Mg−5vol.%B₄C composite exhibited a Young’s modulus of 55.2 GPa, indicating a 23.5% increment over that of pure Mg and in good agreement with the results from the Hashin−Shtrikman (H−S) model. However, a higher B₄C_np content reduced the efficiency of modulus enhancement due to nanoparticle agglomeration and interfacial reaction. The Mg−5vol.%B₄C composite also achieved yield strength and ultimate tensile strength improvements of 16.8% and 9.1%, respectively. Quantitative analysis indicated that thermal mismatch strengthening was the dominant strengthening mechanism, while both thermal mismatch strengthening and Orowan strengthening showed size-dependent behavior linked to nanoparticle clustering.

Friction stir additive manufacturing (FSAM) is one of the most suitable processes for the manufacturing of Al/Mg dissimilar laminated composites. In this study, the single-layer single-pass FSAM and single-layer multi-pass FSAM of Al/Mg dissimilar alloys were conducted. The surface forming, macroscopic metallography, microstructure and mechanical properties were investigated. In the single-layer single-pass FSAM, the sample exhibited a peak tensile strength of 194 MPa at a rotation speed of 800 r/min and a travel speed of 75 mm/min, which was about 79.5% that of the Mg base metal. Components with good mechanical properties were obtained under low-heat-input conditions. In multi-pass FSAM, the thickness of intermetallic compounds decreased gradually from the first pass to the fourth pass. The maximum tensile strength of the alloy was obtained at 800 r/min and 75 mm/min. The tensile strength from the first pass to the fourth pass increased due to the increase of friction stir repetitions.

Young’s modulus, hardness, wear resistance, and hot processability of BCC Ti−V−Cr−Mo alloys were evaluated using high-throughput experimental methods combined with the CALculation of PHAse Diagrams (CALPHAD) approach. Five quaternary solid/solid diffusion couples were annealed at 1473 K for 24 h. Electron probe microanalysis and nanoindentation were used to determine the composition distribution curves and mechanical properties of the diffusion couples, respectively. Atomic mobility and composition-dependent mechanical property databases for the Ti−V−Cr−Mo system were established. The highly efficient numerical inverse method enabled the high-throughput determination of interdiffusivities at 1473 K. The results indicate that BCC Ti−V−Cr−Mo alloys possess high hardness, excellent wear resistance, and good hot processability. This study provides an effective tool for selecting suitable Ti−V−Cr−Mo alloys for hydrogen storage material requirements, and also elucidates the relationship between composition and mechanical properties of Ti−V−Cr−Mo alloys.

Ti–Zr alloy with a heterogeneous structure containing Zr-rich laths was prepared using powder metallurgy and hot extrusion processes. The material exhibits an excellent combination of strength and plasticity under quasi-static conditions. A comprehensive investigation of the Ti−Zr alloy was conducted through combined quasi-static (10⁻³ s⁻¹) and dynamic (800−3000 s⁻¹) compression tests across temperatures ranging from 25 to 700 °C, enabling systematic evaluation of competing effects: strain hardening, strain-rate strengthening, and thermal softening. Under dynamic loading at 25 °C, the deformation mechanism is jointly dominated by dislocation slip and twinning, with a flow stress of 1549.1 MPa, exhibiting a significant strain-rate strengthening effect. At high temperatures, the formation of adiabatic shear bands and the thermal softening effect reduce the flow stress of the material and increase the plasticity. The Johnson−Cook (JC) constitutive model was employed to simulate the dynamic stress–strain curves of the Ti−Zr alloy, demonstrating good agreement with experiments at room temperature and intermediate temperatures.

The effects of pulse current on recrystallization, dislocation density, deformation coordination, and texture evolution in Ti60 alloy were investigated through an electro-assisted tensile test under five different current densities. The results demonstrate that increasing current density significantly promotes atomic diffusion and dislocation annihilation, facilitating grain boundary migration and recrystallization. Enhanced pulse currents improve deformation coordination and overall formability of the Ti60 alloy. At a current density of 30 A/mm², two dominant textures are observed, and the presence of multiple preferred planes at this level indicates superior plasticity compared to other conditions. Moreover, the Joule heating effect below 30 A/mm² primarily activates the basal <a> slip system as the main slip mechanism, while the athermal effect above 30 A/mm² favors the prismatic <a> slip system as the dominant slip mechanism. Among the tested conditions, 30 A/mm² achieves the most favorable balance between microstructural and mechanical performance, making it the optimal current density in this study.

By integrating multiple characterization techniques including XRD, XPS, FIB-TEM, and EPMA, the anisotropic corrosion behavior of La-modified CMSX-4 superalloy was systematically studied. Results indicate that the (111) orientation exhibits better corrosion resistance during the initial stage, while the (100) orientation performs better during the propagation stage. Mechanism analysis shows that the dense atomic structure of the (111) orientation facilitates the formation of a protective surface layer in the early stage. However, during propagation, Ta₂O₅ formation on the (110) and (111) orientations disrupted Cr₂O₃ growth, while element depletion at the corrosion front impeded protective film repair. Conversely, the (100) orientation benefited from rapid cation diffusion and the surface enrichment of Ti and Cr, which enhanced oxide film stability and protective properties, ultimately ensuring superior performance. These results can provide theoretical guidance for the casting and service failure of single-crystal blades with complex geometries.

The effect of Zr content on the microstructural evolution and mechanical properties of Cu−20Ni−20Mn−xZr alloys was studied using uniaxial tensile testing, scanning electron microscopy, and transmission electron microscopy. The results showed that the addition of an appropriate amount of Zr helped to improve both the strength and elongation. Specifically, the Cu−20Ni−20Mn−0.4Zr alloy exhibited optimal overall mechanical properties with a tensile strength of 1680 MPa, an elongation of 5.1%, and an elastic modulus of 167 GPa. The strengthening effect was mainly attributed to the addition of Zr, which reduced the stacking fault energy of the alloy matrix and induced a twinning-induced plasticity effect.

The influence of various oxidants (H₂O₂, Na₂MoO₄ and KMnO₄) on the anti-corrosion and self-healing properties of Ce-based conversion coatings (CeCCs) on AM60B magnesium alloy was systematically investigated via FTIR, SEM, XRD and electrochemical techniques. The results revealed that the incorporation of Na₂MoO₄ and KMnO₄ effectively suppressed crack formation in the coatings, thereby enhancing their corrosion resistance. Specifically, the CeCCs with KMnO₄ exhibited a total impedance of 17 kΩ·cm², significantly higher than 7.6 kΩ·cm² observed for the oxidant-free coating. Notably, the KMnO₄-modified coating demonstrated superior corrosion resistance and self-healing performance, which was attributed to the spontaneous reaction of MnOOH generated during corrosion with Mg²⁺ and OH⁻ to form protective layered double hydroxides. The overall effectiveness of the oxidants followed the following decreasing order: KMnO₄ > Na₂MoO₄ > H₂O₂, in terms of film-forming efficiency, corrosion resistance and self-healing capability. Finally, the formation mechanism and self-healing behavior of CeCCs on AM60B were discussed.

A liquid-phase hydrogen reduction strategy for synthesizing highly dispersed Pt/C catalysts with enhanced oxygen reduction reaction (ORR) performance was proposed. The thermodynamic feasibility of reducing chloroplatinic acid to metallic platinum in solution was evaluated using HSC Chemistry software. The effects of carbon support modification and solution pH on the catalytic activity of Pt/C catalysts were studied. Air calcination of carbon materials (ECP600JD and XC-72R) significantly increased the defect density within the carbon matrix, thereby improving the anchoring efficiency of Pt nanoparticles and enhancing the catalytic stability. The prepared Pt/C (pH 6.34) catalyst exhibited uniformly dispersed Pt nanoparticles with an average size of (2.35±0.3) nm, an electrochemically active surface area of 73.04 m²/g, and a mass activity of 0.245 A/mg at 0.9 V (vs RHE). After 20000 durability cycles, the catalyst retained a mass activity of 0.189 A/mg, which is 1.47 times as high as that of commercial Pt/C (TKK) under identical testing conditions.