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Design, Development and Processing of Aluminium Alloys and Their Composite...
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Design, Development and Processing of Aluminium Alloys and Their Composite Materials

A special issue of Crystals (ISSN 2073-4352). This special issue belongs to the section "Crystalline Metals and Alloys".

Deadline for manuscript submissions: closed (15 December 2025) | Viewed by 22306

Special Issue Editors

Dr. Peng Tang

E-Mail Website
Guest Editor
School of Resources, Environment and Materials, Guangxi University, Nanning 530004, China
Interests: materials science and engineering; additive manufacturing; mechanics of materials
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Mingyi Zheng

E-Mail Website
Guest Editor
School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, China
Interests: Mg alloys; severe plastic deformation; microstructure; texture; advanced experimental characterization
Special Issues, Collections and Topics in MDPI journals
Dr. Kang Wang

E-Mail Website
Guest Editor
School of Materials Science and Engineering, Dongguan University of Technology, Dongguan, China
Interests: additive manufacturing; light alloys; casting; numerical simulations; neutron diffraction
Dr. Xingzhi Pang

E-Mail Website
Guest Editor
School of Resources, Environment and Materials, Guangxi University, Nanning 530004, China
Interests: non-ferrous metal processing; Cu/C composite materials; biomedical materials; solid waste recycling; first-principles calculation

Special Issue Information

Dear Colleagues, 

Aluminium, the most abundant metallic element in the Earth's crust, is one of the most widely used non-ferrous metals in industry, second only to iron and steel in terms of its scope of use because of its good characteristics—low density, high specific strength, workability, and electrical conductivity, superior corrosion resistance, environmental protection and recyclability—and wide range of applications in the aviation, aerospace, construction engineering, and transportation fields.

The design, development, and processing of aluminium alloys and their composites occupy a pivotal position in modern industry to further enhance their toughness, wear resistance, and shear properties. In the case of aluminium alloy composites, researchers have effectively improved the materials’ toughness and wear resistance by introducing various reinforcing phases, such as ceramic particles, carbon nanotubes, and graphene. In this process, the nature, content, and distribution of the reinforcing phase, as well as its interfacial bond strength and wettability with the metal matrix, are the key factors determining the mechanical properties of metal matrix composites. Therefore, the ideal reinforcing phase not only needs to significantly enhance the specific properties of the metal matrix but also have a high degree of stability to avoid violent reactions with the matrix at high temperatures and ensure good metal matrix wettability in order to achieve an effective combination between the two. In addition to material design and development, the processing technology of aluminium alloys and their composites is also key to enhancing their material performance and application scope. Traditional processing methods such as casting, forging, and rolling meet these needs but have limitations, leading researchers to explore new technologies, such as powder metallurgy, EDM, and superplastic forming, to achieve higher precision, lower energy consumption, and better environmental performance.

This Special Issue will focus on the design, development, and processing technologies of aluminium alloys and their composite materials. We warmly invite you to contribute full papers, newsletters, and reviews on the latest developments and research results on this topic. 

Dr. Peng Tang
Prof. Dr. Mingyi Zheng
Dr. Kang Wang
Dr. Xingzhi Pang
Guest Editors

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Crystals is an international peer-reviewed open access monthly journal published by MDPI.

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Keywords

  • aluminium matrix composite materials
  • composition
  • solidification
  • advanced characterization
  • phase composition–property correlation
  • recycled aluminium
  • green low-carbon aluminium alloy system research and development

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Published Papers (15 papers)

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Editorial

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5 pages, 155 KB  
Editorial
The Design, Development and Processing of Aluminium Alloys and Their Composite Materials
by Peng Tang, Mingyi Zheng, Kang Wang and Xingzhi Pang
Crystals 2026, 16(4), 237; https://doi.org/10.3390/cryst16040237 - 2 Apr 2026
Viewed by 247
Abstract
Aluminium, as the most abundant metallic element in the Earth’s crust, holds a pivotal position in modern industry due to its exceptional combination of a low density, high specific strength, excellent workability, superior corrosion resistance, and remarkable recyclability [...] Full article
(This article belongs to the Special Issue Design, Development and Processing of Aluminium Alloys and Their Composite Materials)

Research

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14 pages, 3516 KB  
Article
Effect of Fe Content on the Microstructure and Properties of 5083 Aluminum Alloy
by Jun Cao, Wenjia Zhao, Jiaxing Li, Hongqun Tang, Xu Zheng, Kezhun He, Qizhong Zhao, Hongchi Yang, Xianye Lu, Shengyuan Lei and Chunhua Wei
Crystals 2026, 16(3), 192; https://doi.org/10.3390/cryst16030192 - 11 Mar 2026
Cited by 1 | Viewed by 257
Abstract
To address the challenge of controlling Fe impurity content during the recycling of aluminum alloys, this study utilized commercial 5083 aluminum alloy as a matrix to prepare alloy samples with four different Fe contents via smelting. The effects of Fe content on the [...] Read more.
To address the challenge of controlling Fe impurity content during the recycling of aluminum alloys, this study utilized commercial 5083 aluminum alloy as a matrix to prepare alloy samples with four different Fe contents via smelting. The effects of Fe content on the microstructure, mechanical properties, and corrosion resistance of the as-cast 5083 aluminum alloy were systematically investigated. The results indicate that increasing the Fe content induces a significant morphological evolution of the Fe-rich phases, transitioning from compact Chinese-script α-Al(Fe,Mn)Si phases at low Fe levels to coarse needle-like β-AlFeSi phases. Concurrently, both the quantity and size of the second phases increase significantly. Mechanical testing reveals that the hardness of the alloy gradually rises from 67 HV to 72 HV due to second-phase strengthening. The tensile strength shows a trend of initially increasing and then decreasing, peaking at 0.45 wt.% Fe; however, excessive Fe leads to the formation of needle-like phases that cause stress concentration, resulting in a decline in tensile strength. The elongation decreases gradually with increasing Fe content, with a maximum reduction of 19.7%. Electrochemical tests show that higher Fe content increases the self-corrosion current density and decreases the capacitive loop radius, indicating a significant degradation in the alloy’s corrosion resistance. This work provides an experimental basis for the tolerance control of Fe impurities and the performance optimization of recycled 5083 aluminum alloys. Full article
(This article belongs to the Special Issue Design, Development and Processing of Aluminium Alloys and Their Composite Materials)
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16 pages, 7884 KB  
Article
Effect of Yttrium on Iron-Rich Phases and Mechanical Properties of As-Cast Al-Fe Alloy with Low Si Concentration
by Wenjie Wu, Wenxia Lai, Ziteng Cao, Chengdong Li and Mei Zhao
Crystals 2026, 16(1), 28; https://doi.org/10.3390/cryst16010028 - 30 Dec 2025
Cited by 14 | Viewed by 497
Abstract
In Al–Fe alloys, the mechanical properties are determined by the morphology of iron-rich phases. In this work, AA8176(Al-1Fe)-nY (n = 0, 0.3, 0.5, 0.7, and 0.9 wt.%) alloys were prepared by the cast method. The effects of yttrium (Y) addition on the [...] Read more.
In Al–Fe alloys, the mechanical properties are determined by the morphology of iron-rich phases. In this work, AA8176(Al-1Fe)-nY (n = 0, 0.3, 0.5, 0.7, and 0.9 wt.%) alloys were prepared by the cast method. The effects of yttrium (Y) addition on the microstructure and mechanical properties of AA8176 alloy were studied using various techniques including optical microscopy (OM), scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD), cooling curve analysis and tensile tests. The results revealed that the optimal refinement effect was achieved when the amount of Y content was 0.5 wt.%. When the Y content increased from 0 to 0.5 wt.%, the coarse needle-like Al13Fe4 phases were gradually transformed into short rod-like morphology and some fine Al10Fe2Y phases were formed around the Al13Fe4 phases. The average length of iron-rich phases was decreased from 10.01 μm to 2.65 μm. Additionally, as the Y content increased from 0 to 0.5 wt.%, the secondary dendrite arm spacing (SDAS) of AA8176 alloy was reduced from 31.33 μm to 20.24 μm. Furthermore, the mechanical properties of the AA8176 alloy were improved due to the modified microstructure. With the addition of 0.5 wt.% Y, the ultimate tensile strength, yield strength, elongation, and Vickers hardness were improved to 96.86 MPa, 57.21 MPa, 23.1%, and 30.55 HV, respectively, compared to 84.47 MPa, 50.71 MPa, 18.6%, and 27.28 HV for the unmodified AA8176 alloy. It is proposed that the growth of α-Al dendrite and Al13Fe4 phases were effectively inhibited by segregation of Y atoms around α-Al dendrite and Al13Fe4 phases during solidification. And the Al10Fe2Y phases were formed by these Y atoms with Al and Fe elements. However, the formation of coarse Al10Fe2Y phases was promoted by excessive Y content, resulting in a substantial degradation in mechanical properties. Full article
(This article belongs to the Special Issue Design, Development and Processing of Aluminium Alloys and Their Composite Materials)
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19 pages, 7897 KB  
Article
The Typical Microstructure of Twin-Roll Cast 2139 Alloy and Its Impact on Mechanical Properties
by Zhenkuan Liu, Yuxiao Wang, Qiaoning Chen, Longzhou Meng, Zhengcheng Yang, Hongqun Tang, Xiaoming Qian, Yifei Xu, Yong Li and Xu Li
Crystals 2026, 16(1), 13; https://doi.org/10.3390/cryst16010013 - 24 Dec 2025
Cited by 1 | Viewed by 364
Abstract
The typical microstructure and mechanical properties of twin-roll cast (TRC) 2139 aluminum alloy were investigated and compared with mold casting (MC) 2139 alloy. This work pioneers the application of TRC to produce 2139 Al-Cu-Mg alloy, a material that is challenging for rapid solidification. [...] Read more.
The typical microstructure and mechanical properties of twin-roll cast (TRC) 2139 aluminum alloy were investigated and compared with mold casting (MC) 2139 alloy. This work pioneers the application of TRC to produce 2139 Al-Cu-Mg alloy, a material that is challenging for rapid solidification. The TRC process resulted in a denser dendritic structure, with the composition of intermetallic compounds, primarily Al2Cu and Al2CuMg, remaining largely stable throughout the casting process. After solution treatment, the recrystallized grains in the MC sheets were uniformly distributed, while the TRC sheets exhibited a more localized and refined recrystallized microstructure, particularly within coarse second-phase regions. Following heat treatments, the TRC sheets showed a significant increase in the Ω phase after T6, with a slight growth in size and a uniform distribution, while the Ω phase in T8 showed an increased density and smaller size, which diffused evenly across the material. The TRC process uniquely refines the microstructure and enhances Ω phase precipitation, yielding a 10%+ improvement in strength and ductility over conventional casting. The mechanical properties of the TRC sheets improved significantly: tensile and yield strengths increased by over 10% after T6, compared to MC sheets, with elongation slightly higher in TRC. T8 treatment further enhanced the mechanical properties of the TRC sheets, achieving an improvement in strength with only a minor trade-off in elongation. This establishes TRC as a superior industrial route for high-performance aluminum sheets, offering a promising industrial route, delivering substantial improvements in both strength and ductility over conventional casting methods. Full article
(This article belongs to the Special Issue Design, Development and Processing of Aluminium Alloys and Their Composite Materials)
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10 pages, 1512 KB  
Article
Research on the Efficient Desilication Process of Low-Grade Bauxite in Guangxi
by Guoxian Hu, Anmin Li, An Xia, Dongjie Zhang, Liwen Pan, Xiaolian Zhao and Xingzhi Pang
Crystals 2025, 15(8), 675; https://doi.org/10.3390/cryst15080675 - 24 Jul 2025
Cited by 1 | Viewed by 1679
Abstract
With the continuous exploitation of bauxite mineral resources, Guangxi bauxite faces many difficulties in alumina production due to its characteristics of high silicon content, high iron content, and a low Al-Si ratio. In view of this, this study is closely related to the [...] Read more.
With the continuous exploitation of bauxite mineral resources, Guangxi bauxite faces many difficulties in alumina production due to its characteristics of high silicon content, high iron content, and a low Al-Si ratio. In view of this, this study is closely related to the key link of bauxite pre-desiliconization and strives to break free from the status quo to improve the aluminum/silicon ratio and help optimize the subsequent alumina-refining process. In the work presented in this paper, the unique mineralogy of Guangxi bauxite was comprehensively considered, covering its complex mineral composition and fine distribution characteristics. The barium hydroxide pre-desilication technology was first used for in-depth experimental exploration, and the silicon removal efficiency under different working conditions was systematically compared. The system compared the silicon removal effect and the associated aluminum loss under different working conditions. The results of this study will lay a solid foundation for the rational and efficient development of bauxite in Guangxi, which is expected to reduce the cost of alumina production, improve the economic benefits for the Guangxi aluminum industry, simultaneously strengthen the efficiency of resource recycling, accelerate the sustainable development of the industry, and provide a useful reference example for subsequent similar studies. Full article
(This article belongs to the Special Issue Design, Development and Processing of Aluminium Alloys and Their Composite Materials)
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16 pages, 8434 KB  
Article
Micro-Alloying with Samarium to Enhance the Thermal Conductivity and Mechanical Properties of Al-5Ni Cast Alloys
by Yi Huang, Kang Wang, Zhisheng Zhu, Wenxue Cheng and Wenfang Li
Crystals 2025, 15(7), 609; https://doi.org/10.3390/cryst15070609 - 30 Jun 2025
Cited by 2 | Viewed by 808
Abstract
The research focuses on how the samarium (Sm) addition amount affects the microstructural development, mechanical characteristics, and thermal conductivity of Al-5wt%Ni alloys. Microstructural characterization revealed that minor Sm additions concurrently refined α-Al grains and eutectic structures (α-Al + Al3Ni), attributed to [...] Read more.
The research focuses on how the samarium (Sm) addition amount affects the microstructural development, mechanical characteristics, and thermal conductivity of Al-5wt%Ni alloys. Microstructural characterization revealed that minor Sm additions concurrently refined α-Al grains and eutectic structures (α-Al + Al3Ni), attributed to the reduced initial nucleation temperature of α-Al and an adsorption inhibition effect on Al3Ni phase formation. The experimental findings revealed that the integration of Sm improved the yield strength, maximum tensile strength, and heat conduction. The enhancements were chiefly driven by three processes: the refinement of grains, the improvement of the eutectic structure’s morphology, and diminishing the dissolvability of Fe/Si impurities within the α-Al matrix. The combined improvement of mechanical and thermal characteristics via regulated Sm addition offers a hopeful approach for the microstructural design of Al-Ni alloys. This study provides a crucial basis for the production of Al-Ni alloys that possess high thermal conductivity and satisfactory mechanical properties. Full article
(This article belongs to the Special Issue Design, Development and Processing of Aluminium Alloys and Their Composite Materials)
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18 pages, 12852 KB  
Article
Effect of Al-5Ti-2B on the Microstructure and Mechanical Properties of Recycled Al-7Si-0.3Mg-1Fe Alloy
by Weihe Shi, Lin Chen, Bing He, Biwang Lu and Jianbing Yang
Crystals 2025, 15(7), 584; https://doi.org/10.3390/cryst15070584 - 20 Jun 2025
Cited by 1 | Viewed by 981
Abstract
This study systematically investigates the influence of grain refinement on the microstructural evolution and mechanical properties of recycled Al-7Si-0.3Mg-1Fe alloy through the addition of varying concentrations (0–1.25 wt.%) of Al-5Ti-2B master alloy. The synergistic effects of Al-5Ti-2B on the α-Al phase, eutectic Si, [...] Read more.
This study systematically investigates the influence of grain refinement on the microstructural evolution and mechanical properties of recycled Al-7Si-0.3Mg-1Fe alloy through the addition of varying concentrations (0–1.25 wt.%) of Al-5Ti-2B master alloy. The synergistic effects of Al-5Ti-2B on the α-Al phase, eutectic Si, and Fe-rich intermetallics were characterized using metallographic analysis, XRD, SEM-BSE imaging, and EDS. In the unrefined alloy, the microstructure consisted of an α-Al solid solution with coarse plate-like eutectic Si, while Fe primarily formed needle-like β-Al5FeSi phases that either surrounded or penetrated the eutectic Si. Increasing the Al-5Ti-2B addition refined both the α-Al dendrites and eutectic Si, while the β-Al5FeSi phase transitioned from coarse to fine needles. The optimal refinement was achieved at a 1% Al-5Ti-2B addition, yielding a tensile strength of 149.4 MPa and elongation of 4.3%. However, excessive addition (1.25%) led to eutectic Si aggregation and β-Al5FeSi coarsening, resulting in mechanical property deterioration and brittle fracture behavior. These findings provide insights into optimizing grain refinement for enhancing the performance of recycled Al-Si-Mg-Fe alloys. Full article
(This article belongs to the Special Issue Design, Development and Processing of Aluminium Alloys and Their Composite Materials)
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13 pages, 4469 KB  
Article
Interactions Between Sc2O3 Ceramics and Calcium–Magnesium–Alumina–Silicate (CMAS) at Elevated Temperature
by Zupeng Mo, Zijian Mo, Zhiyun Yu, Yifan Cheng, Yiling Miao and Tianquan Liang
Crystals 2025, 15(2), 198; https://doi.org/10.3390/cryst15020198 - 19 Feb 2025
Cited by 1 | Viewed by 1164
Abstract
The thermochemical interactions of Sc2O3 ceramics with CMAS at 1250 °C and 1300 °C were investigated in this paper. A continuously dense reaction layer (DRL) forms on the surface of the ceramic at the beginning of the reaction within 15 [...] Read more.
The thermochemical interactions of Sc2O3 ceramics with CMAS at 1250 °C and 1300 °C were investigated in this paper. A continuously dense reaction layer (DRL) forms on the surface of the ceramic at the beginning of the reaction within 15 min, and temperature significantly affects the components of the DRL. The DRL is mainly composed of a diopside phase at 1250 °C, whose thickness decreases with reaction time, while it is composed of garnet and minor diopside phases at 1300 °C, and thickens in accordance with the parabolic law with exposure time. The DRL shows good effect on alleviating Mg2+ infiltration and some mitigating effect to Al3+, and relatively inferior resistance to Ca2+ and Si4+ penetration. The concentration of Sc3+ in the residual CMAS increases with reaction temperature and time, and the average contents are about 0.7 at% and 3.7 at% after reactions at 1250 °C and 1300 °C, respectively. The mechanism is discussed systematically. Full article
(This article belongs to the Special Issue Design, Development and Processing of Aluminium Alloys and Their Composite Materials)
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19 pages, 8425 KB  
Article
Spectroscopic Ellipsometry and Wave Optics: A Dual Approach to Characterizing TiN/AlN Composite Dielectrics
by Mohamed El Hachemi, Nikhar Khanna and Emanuele Barborini
Crystals 2025, 15(2), 143; https://doi.org/10.3390/cryst15020143 - 29 Jan 2025
Cited by 1 | Viewed by 1138
Abstract
In this paper, we present a method for retrieving the optical properties of a nano-designed TiN/AlN composite dielectric, using spectroscopic ellipsometry for experimental measurements and wave optics simulations for numerical analysis. Composite cermets have gained attention for solar–thermal energy conversion, but [...] Read more.
In this paper, we present a method for retrieving the optical properties of a nano-designed TiN/AlN composite dielectric, using spectroscopic ellipsometry for experimental measurements and wave optics simulations for numerical analysis. Composite cermets have gained attention for solar–thermal energy conversion, but their fundamental optical properties are not well understood. While characterizing uniformly deposited layers is generally straightforward, the process becomes more complex for nanoparticulate composites. The refractive index is essential for investigating and tuning the optical characteristics of the composite. Our method employs COMSOL Multiphysics software, validated by experimental spectroscopic ellipsometry studies. The strong agreement between experimental and numerical results supports this approach as a rational way to design material models for optical property studies across a broad spectrum. Full article
(This article belongs to the Special Issue Design, Development and Processing of Aluminium Alloys and Their Composite Materials)
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15 pages, 5538 KB  
Article
Effect of Y on the Microstructures and Heat-Resistant Property of ZL109 Alloys
by Xiangdu Qin, Anmin Li and Xiang Li
Crystals 2025, 15(1), 75; https://doi.org/10.3390/cryst15010075 - 14 Jan 2025
Cited by 1 | Viewed by 1553
Abstract
The effects of rare earth Y on the microstructures and tensile properties of ZL109 alloys were studied through metallographic observation, scanning electron microanalysis, X-ray diffraction, and tensile experiments, and the existence form and mechanism of Y were analyzed. The results show that the [...] Read more.
The effects of rare earth Y on the microstructures and tensile properties of ZL109 alloys were studied through metallographic observation, scanning electron microanalysis, X-ray diffraction, and tensile experiments, and the existence form and mechanism of Y were analyzed. The results show that the grain size of the ZL109 alloy is obviously reduced and that the strength of the ZL109 alloy is significantly increased after adding the Y element. When the Y content is increased to 0.2 wt.%, the tensile properties of the ZL109 alloy at room temperature and 350 °C are better than those without a rare earth addition, and the comprehensive tensile properties are better. This is due to the addition of the Y element; α-Al dendrites are obviously refined, and there is a tendency for them to change into fine isometric crystals. The size of the eutectic Si decreases, and its shape is modified. The morphology and size of high temperature enhanced phases, such as Al3CuNi, are optimized. The heat-resistant enhanced phase Al2Si2Y is formed after the addition of rare earth Y. However, with the addition of the Y element, the Al2Si2Y phase increases, and coarsening results in the decrease in alloy strength. Full article
(This article belongs to the Special Issue Design, Development and Processing of Aluminium Alloys and Their Composite Materials)
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19 pages, 9493 KB  
Article
Numerical Simulation and Process Optimization of Laser Welding in 6056 Aluminum Alloy T-Joints
by Jin Peng, Shihua Xie, Tiejun Chen, Xingxing Wang, Xiaokai Yu, Luqiang Yang, Zenglei Ni, Zicheng Ling, Zhipeng Yuan, Jianjun Shi and Zhibin Yang
Crystals 2025, 15(1), 35; https://doi.org/10.3390/cryst15010035 - 30 Dec 2024
Cited by 50 | Viewed by 2734
Abstract
This paper conducts a numerical simulation of the laser welding process for 6056 aluminum alloy stringers and skin T-joints using Simufact Welding. Initially, the accuracy of the finite element simulation is validated, followed by an exploration of the impact of bilateral asynchronous and [...] Read more.
This paper conducts a numerical simulation of the laser welding process for 6056 aluminum alloy stringers and skin T-joints using Simufact Welding. Initially, the accuracy of the finite element simulation is validated, followed by an exploration of the impact of bilateral asynchronous and bilateral synchronous laser welding on molten pool stability. Process parameters, including laser power, welding speed, fixture clamping force, and preheat temperature, are optimized through orthogonal testing. Furthermore, the influence of welding sequences on post-weld equivalent stress and deformation in three stringers’ T-joints is analyzed. The numerical simulation results indicate that the stability of the molten pool is superior in bilateral synchronous welding compared to asynchronous welding. Optimized process parameters were obtained through orthogonal testing, and subsequent experiments demonstrated that the welding sequence of welding both sides first, followed by the middle, produced lower post-weld equivalent stress and reduced overall joint deformation. Full article
(This article belongs to the Special Issue Design, Development and Processing of Aluminium Alloys and Their Composite Materials)
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16 pages, 4348 KB  
Article
Understanding the Interface Characteristics Between TiB2(0001) and L12-Al3Zr(001): A First-Principles Investigation
by Xingzhi Pang, Loujiang Yang, Hang Nong, Mingjun Pang, Gaobao Wang, Jian Li, Zhenchao Chen, Wei Zeng, Zhihang Xiao, Zengxiang Yang and Hongqun Tang
Crystals 2024, 14(11), 979; https://doi.org/10.3390/cryst14110979 - 14 Nov 2024
Cited by 2 | Viewed by 2003
Abstract
This study employs first-principles calculation methods to explore the characteristics of the TiB2(0001)/L12-Al3Zr(001) interface, including the atomic structure, adhesion work, interfacial energy, and electronic structure of various interface models. Considering four different terminations and three different stacking [...] Read more.
This study employs first-principles calculation methods to explore the characteristics of the TiB2(0001)/L12-Al3Zr(001) interface, including the atomic structure, adhesion work, interfacial energy, and electronic structure of various interface models. Considering four different terminations and three different stacking positions, twelve potential interface models were investigated. Surface tests revealed that a stable interface could be formed when a 9-layer TiB2(0001) surface is combined with a 7-layer ZrAl-terminated and a 9-layer Al-terminated Al3Zr(001) surface. Among these interfaces, the bridge-site stacking at the T/Al termination (TAB), hollow-site stacking at the Ti/ZrAl termination (TZH), top-site stacking at the B/Al termination (BAT), and hollow-site stacking at the B/ZrAl termination (BZH) were identified as the optimal structures. Particularly, the TAB interface exhibits the strongest adhesion strength and the lowest surface energy, indicating the highest stability. A Detailed analysis of the electronic structure further reveals that most interfaces predominantly exhibit covalent bonding, with the TAB, TZH, and BZH interfaces primarily featuring covalent bonds, while the BAT interface displays a combination of ionic and covalent bonds. The study ultimately ranks the stability of the interfaces from highest to lowest as TAB, BZH, TZH, and BAT. Full article
(This article belongs to the Special Issue Design, Development and Processing of Aluminium Alloys and Their Composite Materials)
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20 pages, 11151 KB  
Article
Toughening Mechanism of CaAl12O19 in Red Mud–Al2O3 Composite Ceramics
by Shiwei Jiang, Anmin Li and Zhengliang Wang
Crystals 2024, 14(11), 924; https://doi.org/10.3390/cryst14110924 - 26 Oct 2024
Cited by 2 | Viewed by 1533
Abstract
The utilization of red mud in the production of ceramic products represents an efficient approach for harnessing red mud resources. Composite ceramics were prepared from Al2O3, red mud, and Cr2O3 by atmospheric pressure sintering, and the [...] Read more.
The utilization of red mud in the production of ceramic products represents an efficient approach for harnessing red mud resources. Composite ceramics were prepared from Al2O3, red mud, and Cr2O3 by atmospheric pressure sintering, and the phase composition and microscopic morphology of the composite ceramics were investigated by XRD, SEM, and EDS. The flexural strength and fracture toughness of composite ceramics were measured by three-point bending and SENB methods. The results showed that the composite ceramics sintered at 1500 °C with the addition of 1.5 wt.% Cr2O3 had a flexural strength of 297.03 MPa, a hardness of 17.44 GPa, and a densification of 97.75% and fracture toughness of 6.57 MPa·m1/2. The addition of Cr2O3 helps to improve the low strength of red mud composite ceramic samples. The CaAl12O19 phase can form a similar “endo-crystalline” structure with Al2O3 grains, which changes the fracture mode of the ceramics and thus significantly improves the fracture toughness. The wettability tests conducted on Cu and RM–Al2O3 composite ceramic materials revealed that the composites exhibited non-wetting behavior towards Cu at elevated temperatures, while no interfacial reactions or elemental diffusion were observed. Composites have higher surface energy than Al2O3 ceramic at high temperatures. The present study provides a crucial foundation for enhancing the comprehensive utilization value of red mud and the application of red mud ceramics in the field of electronic packaging. Full article
(This article belongs to the Special Issue Design, Development and Processing of Aluminium Alloys and Their Composite Materials)
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14 pages, 23510 KB  
Article
Experimental Study of Reaming Sizes on Fatigue Life of Cold-Expanded 7050-T7451 Aluminum Alloy
by Muyu Guan, Qichao Xue, Zixin Zhuang, Quansheng Hu and Hui Qi
Crystals 2024, 14(9), 803; https://doi.org/10.3390/cryst14090803 - 11 Sep 2024
Cited by 3 | Viewed by 1839
Abstract
The split-sleeve cold expansion technology is widely used in the aerospace industry, particularly for fastening holes, to enhance the fatigue life of components. However, to ensure proper assembly and improve surface integrity, reaming of the cold-expanded holes is necessary. This study investigates the [...] Read more.
The split-sleeve cold expansion technology is widely used in the aerospace industry, particularly for fastening holes, to enhance the fatigue life of components. However, to ensure proper assembly and improve surface integrity, reaming of the cold-expanded holes is necessary. This study investigates the effects of cold expansion and reaming processes on the fatigue performance of 7050-T7451 aluminum alloy. Fatigue tests, residual stress measurements, and microstructural analyses of the hole edges were conducted on specimens with four different hole diameters after cold expansion and reaming. It was found that the depth of reaming significantly affects fatigue life. During the cold expansion process, the compressive residual stress formed around the hole effectively improves fatigue performance. The experiments demonstrated that reaming by 0.2 mm to 0.4 mm helps eliminate minor defects, thereby improving fatigue life. However, reaming beyond 0.5 mm may lead to stress relief and the removal of dense grains at the hole edges, reducing fatigue life. Therefore, determining the optimal reaming size is crucial for enhancing the reliability of aerospace fasteners. Full article
(This article belongs to the Special Issue Design, Development and Processing of Aluminium Alloys and Their Composite Materials)
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Review

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Review
A Critical Review on Friction Stir Spot Welding of Aluminium Alloys: Tool, Mechanical, and Micro-Structural Characteristics
by Manash J. Borah, Kanta Sarma, Yadaiah Nirsanametla, Barun Haldar, Arpan K. Mondal, Borhen Louhichi and Hillol Joardar
Crystals 2025, 15(9), 755; https://doi.org/10.3390/cryst15090755 - 26 Aug 2025
Cited by 2 | Viewed by 4152
Abstract
Aluminum spot welding is extensively applied in automotive, aerospace, and rail sectors due to its favorable strength-to-weight ratio. While resistance spot welding (RSW) has been the traditional method, its high residual stresses, electrode wear, and limited performance with high-strength aluminum alloys have driven [...] Read more.
Aluminum spot welding is extensively applied in automotive, aerospace, and rail sectors due to its favorable strength-to-weight ratio. While resistance spot welding (RSW) has been the traditional method, its high residual stresses, electrode wear, and limited performance with high-strength aluminum alloys have driven interest toward alternative techniques. Friction stir spot welding (FSSW) offers significant advantages over RSW, linear friction welding (LFW), and hybrid processes, including solid-state joining that minimizes porosity, lower energy consumption, and the elimination of consumable electrodes. Compared to LFW, FSSW requires simpler fixturing and is more adaptable for localized repairs, while offering superior joint surface quality over hybrid laser-assisted methods. Despite these advantages, gaps remain in understanding the influence of process parameters on heat generation, microstructural evolution, and mechanical performance. This review consolidates advancements in tool design, thermal characterization, and weld property for aluminum alloys. It presents comparative insights into temperature distribution, weld strength, hardness variation, and metallurgical transformations reported across studies. By critically synthesizing the earlier works, this work identifies knowledge gaps and potential design improvements, aiming to support the development of more efficient and robust FSSW processes for industrial application. Full article
(This article belongs to the Special Issue Design, Development and Processing of Aluminium Alloys and Their Composite Materials)
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