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High-Strength Lightweight Alloys: Innovations and Advancements
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High-Strength Lightweight Alloys: Innovations and Advancements

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

Deadline for manuscript submissions: 20 October 2026 | Viewed by 4429

Editors

Dr. Reshma Sonkusare

E-Mail Website
Guest Editor
Helmholtz-Zentrum Hereon GmbH, Geesthacht, Germany
Interests: alloy design and development; lightweight alloys; multiscale microstructure characterization; deformation behaviour; sustainable materials; high entropy alloys; magnesium alloys and composites
Dr. Rupesh Chafle

E-Mail Website
Guest Editor
Helmholtz-Zentrum Hereon GmbH, Geesthacht, Germany
Interests: lightweight alloys; microstructure modeling; alloy design and development; phase field simulations; precipitation kinetics; solid-state process simulations

Special Issue Information

Dear Colleagues,

Lightweight, high-strength alloys are at the forefront of modern materials science, playing a crucial role in engineering and industrial applications in aerospace, automotive, defense, and energy sectors. These materials address the growing demand for stronger, more durable, and sustainable solutions while reducing weight for improved efficiency and performance. Key classes of high-strength lightweight alloys include aluminum, titanium, and magnesium alloys, along with multi-principal element alloys. Recent advancements in this field focus on innovative alloy design strategies, microstructural engineering, and novel processing techniques to enhance mechanical properties. Additionally, understanding deformation mechanisms at different length scales is critical for tailoring the mechanical behavior of these alloys. Moreover, computational modeling is increasingly used to predict microstructure–property relationships, accelerating the discovery of new alloys with superior performance.

This Special Issue aims to showcase recent breakthroughs in high-strength lightweight alloys, covering design innovations, processing advancements, deformation behavior, and computational modeling approaches to drive progress in materials for next-generation engineering applications. We invite original contributions in this field.

Dr. Reshma Sonkusare
Dr. Rupesh Chafle
Guest Editors

Manuscript Submission Information

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Keywords

  • high-strength lightweight
  • alloy designing
  • processing
  • microstructural engineering
  • material characterization
  • deformation mechanisms
  • computational modeling
  • sustainability

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Published Papers (5 papers)

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Research

20 pages, 13372 KB  
Article
Comparative Study of Wear Behavior of Hypereutectic Al–Si Piston Alloys Using Experimental and Numerical Methods
by Atanasi Tashev, Valyo Nikolov, Boyan Dochev, Desislava Dimova, Mara Kandeva and Mihail Zagorski
Materials 2026, 19(11), 2253; https://doi.org/10.3390/ma19112253 - 26 May 2026
Viewed by 349
Abstract
This study presents an integrated experimental–numerical approach for evaluating the wear behavior of three non-standardized hypereutectic aluminum–silicon (Al–Si) piston alloys based on the AlSi25CuCr system, namely AlSi25Cu4Cr (M1), AlSi25Cu5Cr (M3), and AlSi25Cu5Cr (M5). The wear coefficient was determined experimentally under boundary-lubrication conditions, while [...] Read more.
This study presents an integrated experimental–numerical approach for evaluating the wear behavior of three non-standardized hypereutectic aluminum–silicon (Al–Si) piston alloys based on the AlSi25CuCr system, namely AlSi25Cu4Cr (M1), AlSi25Cu5Cr (M3), and AlSi25Cu5Cr (M5). The wear coefficient was determined experimentally under boundary-lubrication conditions, while the contact conditions in the piston–cylinder system were evaluated using Finite Element Analysis (FEA) and implemented within the Archard wear model. The results reveal a pronounced inconsistency between hardness and wear resistance. Although hardness increases from 1363 MPa (M1) to 1677 MPa (M5), the corresponding wear depth increases from 13.94 nm to 27.61 nm per engine cycle. This behavior is attributed to differences in microstructural characteristics, particularly the morphology and distribution of silicon particles and intermetallic phases, which significantly influence the tribological performance of hypereutectic Al–Si alloys. The experimentally determined wear coefficient K also shows a significant increase, rising from 12.14 × 10−5 (M1) to 29.59 × 10−5 (M5). The lowest wear is observed for alloy M1, whereas M5 exhibits the poorest tribological performance. These findings demonstrate that microstructural characteristics, particularly the morphology and distribution of silicon particles and intermetallic phases, have a dominant influence over hardness in governing wear behavior. The main scientific contribution lies in the direct coupling of experimentally determined material properties with realistically simulated contact conditions, enabling a quantitative and physically consistent comparison of piston alloys under identical operating regimes. The proposed methodology provides a reliable framework for material selection and optimization of piston alloys with enhanced wear resistance. Full article
(This article belongs to the Special Issue High-Strength Lightweight Alloys: Innovations and Advancements)
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26 pages, 17902 KB  
Article
Improvement of the Surface Layer Properties of 316L Stainless Steel Produced by DMLS Through the Use of a Shot Peening Process
by Kazimiera Dudek, Dominika Grygier and Lidia Gałda
Materials 2026, 19(7), 1293; https://doi.org/10.3390/ma19071293 - 24 Mar 2026
Cited by 1 | Viewed by 454
Abstract
Additive-manufactured (AM) 316L stainless steel, produced via direct metal laser sintering (DMLS) and characterised by a surface topography of high irregularities and tensile residual stresses with specific anisotropy, was subjected to milling and shot peening. The milling process caused a reduction in surface [...] Read more.
Additive-manufactured (AM) 316L stainless steel, produced via direct metal laser sintering (DMLS) and characterised by a surface topography of high irregularities and tensile residual stresses with specific anisotropy, was subjected to milling and shot peening. The milling process caused a reduction in surface topography parameters, but tensile residual stresses increased significantly. The shot peening process was carried out according to the full factorial design 32 and technological parameters such as a shot diameter in the range of 1-3 mm and an air supply pressure between 0.2 and 0.6 MPa. As a result of the experiments and the analysis, reduced surface topography was achieved, and a favourable residual stress state was formed with compressive stresses. The mechanism of the changes was demonstrated via microstructure observation and statistical models obtained by mathematical analysis. Full article
(This article belongs to the Special Issue High-Strength Lightweight Alloys: Innovations and Advancements)
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16 pages, 7206 KB  
Article
Microstructural Characteristics and Mechanical Properties of Al–5Cu–0.4Mg–0.1Zr (–0.4Ag) Alloys Processed by Continuous Cast and Conform Processes
by Yunhai Wang, Qianwang Gao, Quanshi Cheng, Zhongliang Lin, Yongchun Xu, Jie Tang, Hui Zhang, Jie Teng and Fulin Jiang
Materials 2026, 19(5), 846; https://doi.org/10.3390/ma19050846 - 25 Feb 2026
Cited by 1 | Viewed by 529
Abstract
The Al–Cu–Mg–Ag alloys have excellent specific strength, good heat resistance and have a wide range of applications in the aerospace and automotive industries. However, industrial production of such alloys is a great challenge owing to the addition of Ag, which limits their widespread [...] Read more.
The Al–Cu–Mg–Ag alloys have excellent specific strength, good heat resistance and have a wide range of applications in the aerospace and automotive industries. However, industrial production of such alloys is a great challenge owing to the addition of Ag, which limits their widespread application. In this work, the industrial continuous cast and continuous extrusion (Conform) processes were employed to prepare Al–5Cu–0.4Mg–0.1Zr (–0.4Ag) alloys, and the effects of Ag addition on the microstructural characteristics and mechanical properties during processing and heat treatment were investigated. The results indicated that Ag addition significantly refined grain size, increased high-angle grain boundary fraction and grain orientation difference in as-cast Al–5Cu–0.4Mg–0.1Zr (–0.4Ag) alloys, and suppressed excessive grain coarsening during homogenizing annealing. During Conform, Ag further refined grain size, increased subgrain number and enhanced grain orientation difference in extruded alloys. For the aging heat treatment, the T6 process demonstrated superior strengthening effects compared to the T5 process. Following T6 treatment, Ag promoted efficient and uniform precipitation of the Ω (Al2CuMgAg) phase and then significantly enhanced peak hardness (160 HV) and tensile strength (511.46 ± 2.06 MPa). Additionally, Ag accelerated second-phase dissolution throughout the entire process and produced finer, denser ductile dimples on tensile fracture surfaces to gain good strength–ductility balance. Full article
(This article belongs to the Special Issue High-Strength Lightweight Alloys: Innovations and Advancements)
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20 pages, 5967 KB  
Article
Investigation of the Structural, Mechanical and Operational Properties of an Alloy AlSi18Cu3CrMn
by Desislava Dimova, Boyan Dochev, Karel Trojan, Kalina Kamarska, Yavor Sofronov, Mihail Zagorski, Veselin Tsonev and Antonio Nikolov
Materials 2025, 18(23), 5434; https://doi.org/10.3390/ma18235434 - 2 Dec 2025
Viewed by 735
Abstract
A non-standardized hypereutectic aluminum–silicon alloy, AlSi18Cu3CrMn, was developed. To refine the structure of the studied composition, a phosphorus modifier was used in an amount of 0.04 wt %, and a complex modifying treatment was applied by combining the chemical elements of phosphorus, titanium, [...] Read more.
A non-standardized hypereutectic aluminum–silicon alloy, AlSi18Cu3CrMn, was developed. To refine the structure of the studied composition, a phosphorus modifier was used in an amount of 0.04 wt %, and a complex modifying treatment was applied by combining the chemical elements of phosphorus, titanium, boron and beryllium (P, 0.04 wt %; Ti, 0.2 wt %; B, 0.04 wt %; Be, 0.007 wt %). To improve the mechanical and operational properties of the alloy, it was heat-treated (T6) at a temperature of 510–515 °C before quenching, with artificial aging applied at a temperature of 210 °C for 16 h. Phosphorus-modified alloy AlSi18Cu3CrMn was quenched in water at 20 °C, and the combined modified alloy was quenched in water at temperatures of 20 °C and 50 °C. By conducting a microstructural analysis, the free Si crystals and silicon crystals in the composition of the eutectic in the alloy structure were characterized, and by conducting XRD, the presence and type of secondary phases were established. The hardness of the alloy was measured, as well as the microhardness of the α-solid solution. Static uniaxial tensile testing was carried out at normal and elevated temperatures (working temperatures of 200 °C, 250 °C and 300 °C). By using a gravimetric method, the corrosion rate of the alloy in 1 M NaCl and 1 M H2SO4 was calculated. The mass wear, wear intensity and wear resistance of the studied AlSi18Cu3CrMn alloy were determined during reversible reciprocating motion in the boundary-layer lubrication regime. Full article
(This article belongs to the Special Issue High-Strength Lightweight Alloys: Innovations and Advancements)
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17 pages, 4564 KB  
Article
Crystallisation and Microstructure of Sludge Particles in AlSi7Mg Secondary Alloys with Increased Iron Content
by Jarosław Piątkowski, Stanisław Roskosz, Sebastian Stach and Marcin Górny
Materials 2025, 18(21), 4921; https://doi.org/10.3390/ma18214921 - 28 Oct 2025
Cited by 2 | Viewed by 941
Abstract
The significant increase in the importance of silumin recycling in the context of sustainable development is driven by tangible ecological and economic benefits. However, the primary technological challenge associated with using scrap is the accumulation of iron, which promotes the formation of undesirable [...] Read more.
The significant increase in the importance of silumin recycling in the context of sustainable development is driven by tangible ecological and economic benefits. However, the primary technological challenge associated with using scrap is the accumulation of iron, which promotes the formation of undesirable sludge particles, degrading the alloy’s mechanical properties. This paper presents a description of the phase transformations in an AlSi7Mg alloy with increased iron and manganese content. Analysis of data from Differential Scanning Calorimetry (DSC) revealed the primary crystallisation of sludge particles (SP) and the pre-eutectic precipitation of the α-Al15(Fe,Mn)3Si2 phase, which replaced the β-Al5FeSi phase. The remaining constituents of the AlSi7Mg alloy structure—α(Al) solid solution dendrites, the α(Al)+β(Si) eutectic, and the Mg2Si phase—crystallise regardless of the iron, manganese, and chromium content. It was established that the increase in the crystallisation temperature of SP, rich mainly in the elements mentioned above, is directly proportional to the increase in the value of the sludge factor (SF) and ranges from 620 °C (for SF~1.3%) to approx. 645 °C (for SF~3.1%). SEM studies revealed that the combined increase in iron and manganese content not only raises the precipitation temperature of SP but also alters its morphology from single polyhedra to compact, “cluster-like” structures. To avoid the presence of sludge particles in the AlSi7Mg alloy, which have an unfavourable morphology and reduce the yield of the melting process, the SF for high-pressure die-casting should not exceed 2.0%. Full article
(This article belongs to the Special Issue High-Strength Lightweight Alloys: Innovations and Advancements)
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