High-Performance Aluminum Alloy: Design, Strengthening, Manufacturing and Application

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: 10 August 2025 | Viewed by 647

Special Issue Editors


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Guest Editor
School of Engineering, Campus of São João da Boa Vista, São Paulo State University, UNESP, São João da Boa Vista 13876-750, SP, Brazil
Interests: solidification; alloy design; microstructure optimization
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Guest Editor
Department of Materials Engineering, Federal University of São Carlos UFSCar, São Carlos 13565-905, SP, Brazil
Interests: solidification; Al alloys; microstructure; image analysis

Special Issue Information

Dear Colleagues,

High-performance aluminum alloys have emerged as pivotal materials across diverse industries due to their exceptional combination of high strength, being lightweight, and superior thermal and corrosion resistance. Their applications span critical sectors such as aerospace, automotive, construction, and electronics, where materials must meet stringent performance, reliability, and sustainability demands. This Special Issue aims to explore the latest advances in aluminum alloy design, strengthening mechanisms, manufacturing technologies, and applications, providing a platform for researchers and industry experts to share cutting-edge findings.

The design of high-performance aluminum alloys requires balancing complex trade-offs, such as strength versus thermal conductivity. Advanced computational methods have revolutionized alloy development, including machine learning models like XGBoost and Support Vector Machines (SVMs). These tools allow for the precise prediction of mechanical and thermal properties based on compositional attributes, enabling the tailored design of alloys with superior performance metrics. Moreover, CALPHAD (Calculation of Phase Diagrams) is essential in alloy design as it predicts the phase stability, transformations, and thermodynamic properties of materials. This enables the optimization of alloy compositions and processing conditions without extensive experimental trials. Its use accelerates innovation in developing high-performance and sustainable materials.

Strengthening mechanisms, including grain growth control, work hardening, precipitation hardening, and solid solution strengthening, play critical roles in achieving optimal mechanical properties. Advanced manufacturing techniques, such as additive manufacturing, laser-based techniques, and friction stir welding, address challenges like porosity, anisotropy, and residual stress while enabling the production of complex, high-integrity components.

In this Special Issue, we invite contributions focusing on the theoretical, experimental, and computational aspects of high-performance aluminum alloy design and application. Topics of interest for this Special Issue include predictive modeling for alloy development, microstructural engineering, innovative strengthening methods, and advancements in manufacturing technologies. By fostering interdisciplinary collaboration, this Special Issue aims to drive innovation in the field and support the development of next-generation aluminum alloys tailored to modern engineering and sustainable development demands.

Dr. Crystopher Cardoso de Brito
Dr. José Spinelli
Guest Editors

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Keywords

  • high-performance aluminum alloys
  • alloy design and optimization
  • strengthening mechanisms
  • advanced manufacturing technologies
  • aerospace and automotive applications

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Published Papers (1 paper)

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Research

22 pages, 11408 KiB  
Article
The Influence of Beryllium Incorporation into an Al-5wt.%Cu-1wt.%Si Alloy on the Solidification Cooling Rate, Microstructural Length Scale, and Corrosion Resistance
by Joyce Ranay Santos, Milena Poletto Araújo, Talita Vida, Fabio Faria Conde, Noé Cheung, Amauri Garcia and Crystopher Brito
Metals 2025, 15(7), 736; https://doi.org/10.3390/met15070736 - 30 Jun 2025
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Abstract
The addition of beryllium (Be) to Al–Cu alloys enhances their mechanical properties and corrosion resistance. This study aims to investigate the effects of solidification cooling rates and the addition of Be on the microstructural refinement and corrosion behavior of an Al–5wt.%Cu–1wt.%Si–0.5wt.%Be alloy. Radial [...] Read more.
The addition of beryllium (Be) to Al–Cu alloys enhances their mechanical properties and corrosion resistance. This study aims to investigate the effects of solidification cooling rates and the addition of Be on the microstructural refinement and corrosion behavior of an Al–5wt.%Cu–1wt.%Si–0.5wt.%Be alloy. Radial solidification under unsteady-state conditions was performed using a stepped brass mold, producing four distinct cooling rates. An experimental growth law, λ2 = 26T˙1/3, was established, confirming the influence of Be and the cooling rate on dendritic size reduction. The final microstructure was characterized by an α-Al dendritic matrix with eutectic compounds (α-Al + θ-Al2Cu + Si + Fe-rich phase) confined to the interdendritic regions. No Be-containing intermetallic phases were detected, and beryllium remained homogeneously distributed within the eutectic. Notably, Be addition promoted a morphological transformation of the Fe-rich phases from angular or acicular forms into a Chinese-script-like structure, which is associated with reduced local stress concentrations. Tensile tests revealed an ultimate tensile strength of 248.8 ± 11.2 MPa and elongation of approximately 6.4 ± 0.5%, indicating a favorable balance between strength and ductility. Corrosion resistance assessment by EIS and polarization tests in a 0.06 M NaCl solution showed a corrosion rate of 28.9 µm·year−1 and an Epit of −645 mV for the Be-containing alloy, which are lower than those measured for the reference Al–Cu and Al–Cu–Si alloys. Full article
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