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Alloy Strengthening Mechanisms, Microstructure Control and Performance Optimization (Second Edition)
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Alloy Strengthening Mechanisms, Microstructure Control and Performance Optimization (Second Edition)

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Metals and Alloys".

Deadline for manuscript submissions: 20 April 2026 | Viewed by 3749

Special Issue Editors

Dr. Hongling Zhou

E-Mail Website
Guest Editor
College of Materials Science and Engineering, Chongqing University, Chongqing 400044, China
Interests: powder metallurgy; rapid preparation techniques; first-principles calculations; alloy strengthening mechanisms
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Keqin Feng

E-Mail Website
Guest Editor
School of Mechanical Engineering, Sichuan University, Chengdu 610065, China
Interests: metal matrix composites; field-assisted material fabrication; physicochemistry of material preparation and metallurgical processes
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Metals and alloys are pivotal to technological advancements in various engineering sectors. Material properties such as density, strength, electrical and thermal conductivity, tensile performance, ductility, high-temperature properties, and corrosion resistance primarily depend on the regulation of alloy composition and precise control of microstructures, as well as material fabrication and processing methods, among other factors. This second edition focuses on, but is not limited to, exploring the intrinsic mechanisms of alloy strengthening, the underlying mechanisms involved in material fabrication and processing, and the control of microstructures and properties. We aim to compile cutting-edge research and comprehensive reviews on the latest developments in the design, fabrication, forming, processing, characterization, and application of alloys and metal matrix composites. Topics for submission may include the role of computational simulations, sintering, phase transformation, deformation, dislocation theory, nanostructuring, alloying elements, and material forming and processing techniques in the evolution of microstructures and properties.

We warmly invite submissions that extend the boundaries of traditional material fabrication and processing techniques and provide novel insights into alloy strengthening mechanisms, microstructure control, and performance optimization. We eagerly anticipate receiving submissions that not only deepen our understanding through experimental studies but also include theoretical research effectively employing computational simulations to provide valuable guidance for bridging experimental research and industrial applications.

Dr. Hongling Zhou
Prof. Dr. Keqin Feng
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

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. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • metals and alloys
  • metal matrix composites
  • powder metallurgy
  • additive manufacturing
  • forming
  • surface treatment
  • heat treatment
  • materials characterization
  • microstructure evaluation
  • properties
  • phase transformation
  • corrosion
  • numerical simulations

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Related Special Issue

Published Papers (7 papers)

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Research

19 pages, 5717 KB  
Article
Microstructure Evolution Control and Performance Degradation of SA-178 Grade C Boiler Tubes Driven by Pearlite Spheroidization
by Adimas Aprilio Hardinanto, Anne Zulfia Syahrial, Amin Suhadi, Eka Febriyanti, Gilang Cempaka Kusuma, Hamdani, Ridwan, Andon Insani, Muhammad Refai Muslih, Bharoto, Sairun and Suryadi
Materials 2026, 19(2), 270; https://doi.org/10.3390/ma19020270 - 9 Jan 2026
Viewed by 295
Abstract
SA 178 grade C carbon steel is a material commonly used in boiler tubes. Boilers are crucial in the energy industry; however, their service life degrades over time. If a boiler malfunctions, processing operations must be halted, resulting in financial losses for the [...] Read more.
SA 178 grade C carbon steel is a material commonly used in boiler tubes. Boilers are crucial in the energy industry; however, their service life degrades over time. If a boiler malfunctions, processing operations must be halted, resulting in financial losses for the company. The aim of this study is to examine the effect of microstructural evolution, especially the transformation of lamellar pearlite into spheroidized pearlite, on the service life degradation of boiler tubes. Understanding these changes is essential for preventing catastrophic system failures. The methodology involves the use of Small-Angle X-ray Scattering (SAXS) supported by metallographic analysis, Scanning Electron Microscopy (SEM), Energy-Dispersive X-ray (EDX) Spectroscopy, and mechanical testing. The SAXS results indicate that the microstructure of SA 178, which initially consisted of ferrite and lamellar pearlite, gradually transforms into spheroidized pearlite. These microstructural changes lead to reductions in tensile strength from 523 MPa for 0% spheroidization to 335 MPa for 100% spheroidization, as well as a reduction in hardness from 175 HV to 89 HV, ultimately decreasing the service life of the boiler tube. Full article
(This article belongs to the Special Issue Alloy Strengthening Mechanisms, Microstructure Control and Performance Optimization (Second Edition))
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21 pages, 10212 KB  
Article
Numerical Investigation of Material Flow and Defect Formation in FRAM-6061 Al Alloy Ring Component Using CEL Simulation
by Yan Ji and Bin Yang
Materials 2026, 19(2), 236; https://doi.org/10.3390/ma19020236 - 7 Jan 2026
Viewed by 244
Abstract
In this study, a novel and efficient solid-state additive manufacturing technique, friction rolling additive manufacturing (FRAM), was employed to fabricate an aluminum alloy ring component, significantly reducing process complexity and mitigating solidification defects typical of melt-based techniques. However, previous studies on FRAM have [...] Read more.
In this study, a novel and efficient solid-state additive manufacturing technique, friction rolling additive manufacturing (FRAM), was employed to fabricate an aluminum alloy ring component, significantly reducing process complexity and mitigating solidification defects typical of melt-based techniques. However, previous studies on FRAM have primarily focused on the microstructural characteristics and mechanical properties of flat components, with limited attention paid to ring-shaped components. Owing to the unique geometric constraints imposed during the forming process, ring components exhibit markedly different microstructural evolution and defect formation mechanisms compared with flat counterparts, and these mechanisms remain insufficiently and systematically understood. To address this knowledge gap, the coupled Eulerian–Lagrangian (CEL) method was introduced for the first time to numerically simulate the temperature distribution and residual stress evolution during the FRAM process of ring-shaped components. In addition, tracer particles were incorporated into the simulations to analyze the material flow behavior, thereby systematically elucidating the forming behavior and microstructural evolution characteristics under geometric constraint conditions. Moreover, scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD) were employed to systematically characterize the microstructural evolution and defect morphology. The CEL numerical simulations exhibited good consistency with the experimental observations, demonstrating the reliability and accuracy of the simulation method. The results showed that the peak temperatures were primarily concentrated at the advancing side of the rotation tool, and the temperature on the outer diameter side of the ring was consistently higher than that on the inner diameter side. The lack of shoulder friction on the inner side led to an increased heat dissipation rate, thereby resulting in higher residual stress compared to other regions. The particle analysis revealed that, due to ring geometry, material flow varied across radial regions, resulting in distinct microstructures. Further EBSD analysis revealed that, after the rotating tool passed, the material first developed a preferential orientation with {111} planes parallel to the shear direction, and with more layers, dynamic recrystallization produced an equiaxed grain structure. This study provides a theoretical basis and process reference for the application of the FRAM technique in the manufacturing of large ring components. Full article
(This article belongs to the Special Issue Alloy Strengthening Mechanisms, Microstructure Control and Performance Optimization (Second Edition))
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13 pages, 5136 KB  
Article
Precipitation of β-Mn in the Form of Widmanstätten Side-Plates in the Ferrite Matrix of an Fe–28.6 Mn–10.9 Al Alloy Steel
by Rosemary Chemeli Korir and Wei-Chun Cheng
Materials 2026, 19(1), 133; https://doi.org/10.3390/ma19010133 - 30 Dec 2025
Viewed by 336
Abstract
The microstructural evolution and phase stability in Fe–Mn–Al alloys play a decisive role in determining their mechanical performance and potential applications. This study investigates the precipitation behavior and crystallography of the β-Mn phase in an Fe–28.6 Mn–10.9 Al (wt.%) alloy subjected to annealing [...] Read more.
The microstructural evolution and phase stability in Fe–Mn–Al alloys play a decisive role in determining their mechanical performance and potential applications. This study investigates the precipitation behavior and crystallography of the β-Mn phase in an Fe–28.6 Mn–10.9 Al (wt.%) alloy subjected to annealing at 1100 °C, followed by water quenching and subsequent isothermal holding at temperatures between 500 °C and 900 °C for 20 h. Microstructural analysis using X-ray diffraction, optical and electron microscopy revealed a single body-centered cubic (BCC) ferritic matrix above 850 °C and the formation of β-Mn precipitates with Widmanstätten side-plate morphology at lower temperatures. The β-Mn phase was thermally stable between ~500 °C and 850 °C, with the volume fraction increasing with temperature and reaching a maximum near 650 °C. The β-Mn precipitates coarsened progressively with increasing temperature and were found to be richer in Mn than the surrounding Fe-rich BCC matrix. Crystallographic analysis established an orientation relationship (OR) of (021¯)β // (100)α and [1¯12]β // [012]α, where // denotes nearly parallel alignment, signifying a semi-coherent interface between the two structures. These findings clarify β-Mn precipitation, its interfacial relationship with ferrite, and its thermal stability in high-Mn Fe–Mn–Al alloys, offering guidance for microstructural design in next-generation lightweight steels. Full article
(This article belongs to the Special Issue Alloy Strengthening Mechanisms, Microstructure Control and Performance Optimization (Second Edition))
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19 pages, 4026 KB  
Article
Effect of Silicon and Continuous Annealing Process on the Microstructure, Mechanical Properties, and Hydrogen Embrittlement of DP1500 Steel
by Wei Li, Yu Tang, Boyu Cao, Yeqian Jiang, Yang Shen, Wei Li and Ke Zhang
Materials 2026, 19(1), 6; https://doi.org/10.3390/ma19010006 - 19 Dec 2025
Cited by 1 | Viewed by 612
Abstract
Dual-phase (DP) steels are widely used in automotive structures due to their excellent strength–ductility balance. This study examines how silicon content and continuous annealing parameters affect the microstructure, mechanical properties, and hydrogen embrittlement (HE) behavior of DP1500 steel. Two steels, 05DP (0.5% Si) [...] Read more.
Dual-phase (DP) steels are widely used in automotive structures due to their excellent strength–ductility balance. This study examines how silicon content and continuous annealing parameters affect the microstructure, mechanical properties, and hydrogen embrittlement (HE) behavior of DP1500 steel. Two steels, 05DP (0.5% Si) and 15DP (1.5% Si), were processed under annealing temperatures of 800–850 °C and over-aging temperatures of 240–300 °C. Higher annealing temperatures increased austenite formation and produced more martensite after cooling, leading to higher strength but reduced ductility at 850 °C due to martensite coarsening. Increasing the over-aging temperature coarsened carbides and reduced strength yet stabilized retained austenite and improved ductility through the TRIP effect. An increase in silicon content suppressed carbide precipitation, promoted carbon enrichment in austenite, refined the ferrite–martensite structure, and significantly enhanced both strength and elongation. Consequently, 15DP steel exhibited superior mechanical properties compared to 05DP steel, exhibiting 90–100 MPa higher tensile strength (+6.2–7.0%), 55–65 MPa higher yield strength (+5.3–6.2%), and 1.4–1.8 percentage points higher total elongation (+10–14%), resulting in a 16–20% increase in the strength–ductility balance (Rm × A). However, due to the relatively high hydrogen embrittlement susceptibility of fresh martensite formed either by the TRIP effect during deformation or after over-aging, 15DP steel did not exhibit substantially improved HE resistance despite its higher retained austenite fraction. Full article
(This article belongs to the Special Issue Alloy Strengthening Mechanisms, Microstructure Control and Performance Optimization (Second Edition))
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17 pages, 9040 KB  
Article
Effect of Laser Power on the Corrosion and Wear Resistance of Laser Cladding TC4 Alloy
by Xiaolei Li, Sen Zhao, Kelun Zhang, Lujun Cui, Shirui Guo, Bo Zheng, Yinghao Cui, Yongqian Chen, Yue Zhao and Chunjie Xu
Materials 2025, 18(24), 5609; https://doi.org/10.3390/ma18245609 - 14 Dec 2025
Viewed by 425
Abstract
TC4 alloy coatings were fabricated on a titanium alloy substrate using laser cladding. The influence of laser power ranging from 1000 W to 2200 W on the microhardness, wear resistance, and electrochemical corrosion behavior in 3.5% NaCl solution was systematically investigated. Results demonstrate [...] Read more.
TC4 alloy coatings were fabricated on a titanium alloy substrate using laser cladding. The influence of laser power ranging from 1000 W to 2200 W on the microhardness, wear resistance, and electrochemical corrosion behavior in 3.5% NaCl solution was systematically investigated. Results demonstrate that the TC4 coating exhibited a 35.17% enhancement in microhardness compared to the substrate, with an average value reaching 500 HV. As the laser power increased from 1000 W to 2200 W, the maximum wear depth progressively decreased, indicating significantly improved wear resistance, with fatigue wear being identified as the dominant mechanism. The coating prepared at 1400 W showed the best corrosion performance, displaying the highest self-corrosion potential of −0.110 V, the lowest corrosion current density of 0.125 μA·cm−2, and the largest polarization resistance of 2.057 × 106 Ω·cm2. The charge transfer resistance initially increased and then decreased with increasing laser power. Numerical simulations revealed that when exposed to seawater, galvanic couples formed between the α and β phases on the TC4 titanium alloy surface, resulting in preferential dissolution of the β-phase. Full article
(This article belongs to the Special Issue Alloy Strengthening Mechanisms, Microstructure Control and Performance Optimization (Second Edition))
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21 pages, 7800 KB  
Article
Effects of Rolling Parameters on Stress–Strain Fields and Texture Evolution in Al–Cu–Sc Alloy Sheets
by Guoge Zhang, Lijie Liu, Tuo Li, Shan Tang and Bo Gao
Materials 2025, 18(23), 5414; https://doi.org/10.3390/ma18235414 - 1 Dec 2025
Cited by 1 | Viewed by 639
Abstract
This work examines how rolling speed, feeding rate, and pass schedule—with a constant total reduction—affect the stress–strain fields, rolling force, and texture evolution of Al–Cu–Sc alloy sheets. A coupled finite element (FEM) and viscoplastic self-consistent (VPSC) framework is employed and compared with EBSD [...] Read more.
This work examines how rolling speed, feeding rate, and pass schedule—with a constant total reduction—affect the stress–strain fields, rolling force, and texture evolution of Al–Cu–Sc alloy sheets. A coupled finite element (FEM) and viscoplastic self-consistent (VPSC) framework is employed and compared with EBSD measurements to connect macroscopic fields with microscale texture changes. Results indicate that increasing rolling speed raises the effective strain rate and deformation heating, which lowers peak rolling force and improves in-plane stress homogenization on the RD–ND plane, while enhancing surface–core incompatibility and residual-stress gradients along the ND–TD direction. A higher feeding rate mainly intensifies work hardening, slightly elevates rolling force, and promotes near-surface stress/strain localization; in contrast, multi-pass schedules redistribute deformation between passes and reduce macroscopic stress concentration. Texture analyses show a speed-induced rotation from ⟨001⟩ toward ⟨111⟩ orientations, strengthening shear-related components; KAM maps suggest increased local orientation gradients consistent with higher stored energy. The simulations capture the principal experimental trends across conditions, supporting the use of the combined framework for trend-level process guidance. Overall, the findings clarify parameter–microstructure relationships and provide a basis for designing rolling routes that balance force reduction, stress uniformity, and texture control in Al–Cu–Sc sheets. Full article
(This article belongs to the Special Issue Alloy Strengthening Mechanisms, Microstructure Control and Performance Optimization (Second Edition))
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18 pages, 7098 KB  
Article
Microstructural Analysis of Recast Layer Thickness and Microcrack Formation During EDM of Hastelloy C-22 with Different Graphite Electrodes
by Rafał Nowicki and Rafał Świercz
Materials 2025, 18(23), 5338; https://doi.org/10.3390/ma18235338 - 27 Nov 2025
Cited by 1 | Viewed by 741
Abstract
Electrical discharge machining is a non-conventional shaping technique applied to electrically conductive, difficult-to-machine alloys, such as Hastelloy C-22. This study investigates the influence of graphite electrode properties and key machining parameters on the average thickness of the recast layer under positive polarity. Two [...] Read more.
Electrical discharge machining is a non-conventional shaping technique applied to electrically conductive, difficult-to-machine alloys, such as Hastelloy C-22. This study investigates the influence of graphite electrode properties and key machining parameters on the average thickness of the recast layer under positive polarity. Two POCO graphite electrodes with different grain sizes—AF-5 (1 μm) and S-180 (10 μm)—were used to examine the effects of discharge current, pulse duration, and interval on recast layer formation. Metallographic analyses measured layer thickness and observed microstructural defects, including microcracks. Results show that discharge current and pulse duration are the primary factors controlling recast layer thickness, with higher currents and longer pulses producing thicker layers due to resolidification of molten material remaining in the plasma-formed crater. The coarser S-180 electrode caused slightly higher microcrack density and greater thickness variations due to its lower electrical resistivity. Pulse interval mainly influenced discharge stability and debris removal, with minimal effect on average layer thickness. Statistical regression models were developed to quantify the relationships between machining parameters, electrode type, and recast layer thickness, providing predictive tools for selecting optimal conditions. These findings contribute to improving surface integrity and process control in electrical discharge machining of nickel-based alloys. Full article
(This article belongs to the Special Issue Alloy Strengthening Mechanisms, Microstructure Control and Performance Optimization (Second Edition))
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