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Metals
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Advances in Lightweight Alloys, 2nd Edition
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Advances in Lightweight Alloys, 2nd Edition

A Special Issue of Metals (ISSN 2075-4701) belonging to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (25 April 2026) | Viewed by 15697

Editors

Dr. Huarui Zhang

E-Mail Website
Guest Editor
Research Institute for Frontier Science, Beihang University, Beijing 100191, China
Interests: aluminum alloy; Ni-based superalloy; casting; forming; solidification
Special Issues, Collections and Topics in MDPI journals
Dr. Lina Jia

E-Mail Website
Guest Editor
Research Institute for Frontier Science, Beihang University, Beijing 100191, China
Interests: advanced aluminum; aluminum-based composite; Nb-Si based alloy
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

We are delighted to organize a Special Issue entitled “Advances in Lightweight Alloys II”. To meet the requirement of energy saving and emission reduction, lightweight alloys have been widely used in industries such as aerospace, automotives, and railway transportation. Recent research advances enable a better understanding of the relationship between the composition, microstructure, process, and properties of lightweight alloys. The papers presented in this Special Issue contain valuable information about the composition design, preparation process, casting, solidification, microstructure, and property analysis of lightweight alloys, including but not limited to aluminum alloy, magnesium alloy, titanium alloy, and lightweight nickel-based superalloy. We hope this Special Issue will contribute to the ongoing discussions on designing high-performance lightweight alloys and developing advanced processing technology.

Dr. Huarui Zhang
Dr. Lina Jia
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-anonymized peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly 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

  • aluminum alloy
  • magnesium alloy
  • titanium alloy
  • Ni-based superalloy
  • composition design
  • processing technology
  • microstructure analysis
  • mechanical properties

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Related Special Issues

Published Papers (6 papers)

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Research

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14 pages, 5616 KB  
Article
Microstructure and Mechanical Properties in Double-Sided Friction Stir Welded AA 5052-H32 Thick Plate
by Zhuang Shao, Ke Yang, Wenbin Lu, Xuezhi Zhu and Jianhua Zhao
Metals 2026, 16(5), 536; https://doi.org/10.3390/met16050536 - 15 May 2026
Viewed by 554
Abstract
The reliable joining of ultra-thick aluminum alloy plates remains a critical technical challenge in modern industrial manufacturing, often hindered by defects such as porosity and excessive distortion associated with conventional fusion welding. The novelty of this work lies in the characterization of the [...] Read more.
The reliable joining of ultra-thick aluminum alloy plates remains a critical technical challenge in modern industrial manufacturing, often hindered by defects such as porosity and excessive distortion associated with conventional fusion welding. The novelty of this work lies in the characterization of the intermediate layer overlapping zone in 110 mm ultra-thick plates, which has rarely been reported. The motivation is to overcome the limitations of single-pass FSW for thick plates, such as insufficient material flow and high tool forces, by adopting a sequential double-sided strategy. Furthermore, this technique may help moderate the through-thickness heat input variation, although no direct thermal measurements were made. The weld nugget zone consists of uniformly fine, recrystallized α-Al grains. In contrast, the heat-affected zone displays distinctly laminar grain structures. The overlapping regions within the intermediate layer, which undergo two thermal cycles, exhibit refined grain sizes. A well-defined interface is evident between the advancing-side weld nugget zone and the thermo-mechanically affected zone. The overall tensile strength of the FSW joint is approximately 81% of the base material, and the tensile specimen fractured at the interface between the thermo-mechanically affected zone and the heat-affected zone. Along the thickness of the weld joint, a “W”-shaped microhardness distribution is observed at the surface and subsurface, whereas the intermediate layer exhibits a distinct “V”-shaped profile. The lowest microhardness value is located in the intermediate layer overlapping area due to the insufficient heat input and limited grain growth in this region. In summary, under the specific welding parameters tested (130 rpm, 15 mm/min, 110 mm thick), double-sided friction stir welding produces defect-free joints in AA 5052-H32, suggesting its potential for thick-plate applications, offering a practical and effective solution for manufacturing high-performance aluminum alloy structures. Potential industrial applications include pressure vessels for chemical storage, ship hull structures, and heavy-duty transportation components where ultra-thick aluminum plates are required. Full article
(This article belongs to the Special Issue Advances in Lightweight Alloys, 2nd Edition)
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17 pages, 4803 KB  
Article
Effect of Refining Temperature and Refining Time on Purification and Composition Control of FGH95 Powder Metallurgy Superalloy Return Material During Vacuum Induction Melting
by Jiulong Chen, Xuqing Wang, Lei Zhou, Peng Fu, Ying Cheng and Huarui Zhang
Metals 2025, 15(10), 1140; https://doi.org/10.3390/met15101140 - 14 Oct 2025
Cited by 2 | Viewed by 1603
Abstract
To promote the high-value recycling of machining return materials from powder metallurgy (P/M) FGH95 superalloy production, a vacuum induction melting refining process was developed to achieve gas impurity purification and compositional control. Cylindrical solid returns obtained from wire-cut electrical discharge machining were used [...] Read more.
To promote the high-value recycling of machining return materials from powder metallurgy (P/M) FGH95 superalloy production, a vacuum induction melting refining process was developed to achieve gas impurity purification and compositional control. Cylindrical solid returns obtained from wire-cut electrical discharge machining were used as feedstock, and the effects of refining temperature (1550–1650 °C) and holding time (10–30 min) on impurity removal and element stability were systematically investigated. For each condition, three repeated melts were performed, and the average gas contents (mean ± SD) were evaluated by inert-gas fusion analysis. Results show that at 1650 °C, O decreased from 8 ppm to 6 ppm, N decreased from 6 ppm to 3 ppm, while H remained below the detection limit (<1 ppm). Prolonged refining caused slight compositional deviations, with Cr exhibiting measurable volatilization, whereas Al and Ti showed minor increases (<0.06 wt.%). A kinetic model describing O removal was established, yielding an apparent activation energy of 128 kJ·mol−1, confirming diffusion-controlled deoxidation behavior. The optimal refining condition—1650 °C for 10 min—achieved efficient removal of O and H while maintaining alloy compositional stability. This study provides both a practical refining route and a kinetic basis for the purification and reuse of machining returns in nickel-based P/M superalloys, contributing to cost reduction and sustainable manufacturing. Full article
(This article belongs to the Special Issue Advances in Lightweight Alloys, 2nd Edition)
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18 pages, 8196 KB  
Article
Enhancing Aluminum Alloy Properties Through Low Pressure Forging: A Comprehensive Study on Heat Treatments
by Silvia Cecchel and Giovanna Cornacchia
Metals 2025, 15(7), 797; https://doi.org/10.3390/met15070797 - 15 Jul 2025
Viewed by 2373
Abstract
The weight reduction is a key objective in modern engineering, particularly in the automotive industry, to enhance vehicle performance and reduce the carbon footprint. In this context aluminum alloys are widely used in structural automotive applications, often through forging processes that enhance mechanical [...] Read more.
The weight reduction is a key objective in modern engineering, particularly in the automotive industry, to enhance vehicle performance and reduce the carbon footprint. In this context aluminum alloys are widely used in structural automotive applications, often through forging processes that enhance mechanical properties compared to the results for casting. However, the high cost of forging can limit its economic feasibility. Low pressure forging (LPF) combines the benefits of casting and forging, employing controlled pressure to fill the mold cavity and improve metal purity. This study investigates the effectiveness of the LPF process in optimizing the mechanical properties of AlSi7Mg aluminum alloy by evaluating the influence of three different magnesium content levels. The specimens underwent T6 heat treatment (solubilization treatment followed by artificial aging), with varying aging times and temperatures. Microstructural analysis and tensile tests were conducted to determine the optimal conditions for achieving superior mechanical strength, contributing to the design of lightweight, high-performance components for advanced automotive applications. The most promising properties were achieved with a T6 treatment consisting of solubilization at 540 °C for 6 h followed by aging at 180 °C for 4 h, resulting in mechanical properties of σy 280 MPa, σm 317 MPa, and A% 3.5%. Full article
(This article belongs to the Special Issue Advances in Lightweight Alloys, 2nd Edition)
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20 pages, 3323 KB  
Article
Determination of the Corrosion and Biocompatibility Properties of As-Cast TiNi Alloys
by Minja Miličić Lazić, Dijana Mitić, Biljana Dojčinović, Marko Lazić, Aleksandra S. Popović and Branimir N. Grgur
Metals 2025, 15(7), 758; https://doi.org/10.3390/met15070758 - 5 Jul 2025
Cited by 1 | Viewed by 1289
Abstract
In this study, a TiNi alloy with a composition of 50 at.% of titanium and 50 at.% of nickel is investigated in terms of its corrosion and biocompatibility behavior for biomedical applications. The corrosion measurements, which include the determination of open-circuit potential and [...] Read more.
In this study, a TiNi alloy with a composition of 50 at.% of titanium and 50 at.% of nickel is investigated in terms of its corrosion and biocompatibility behavior for biomedical applications. The corrosion measurements, which include the determination of open-circuit potential and linear polarization resistance measurements, cyclic polarization measurements, and electrochemical impedance spectroscopy in 9 g L−1 NaCl, show that TiNi has satisfactory corrosion stability. According to the SEM and EDS analysis, after cyclic polarization, pitting corrosion occurred, accompanied by the dissolution of the unstable Ti2Ni inclusions. The analysis also showed that TiNi has good biocompatibility for human osteoblast-like cells, as determined by the mitochondrial activity, which was assessed using a direct contact test following ISO standard 10993-5, via scanning electron microscopy (SEM) and fluorescent microscopy. Full article
(This article belongs to the Special Issue Advances in Lightweight Alloys, 2nd Edition)
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12 pages, 3201 KB  
Article
Experimental and Numerical Analysis of Friction Effects in the Forming of Thin EN AW 8006-O Aluminum Sheets
by Gianluca Parodo, Luca Sorrentino, Sandro Turchetta and Giuseppe Moffa
Metals 2025, 15(7), 695; https://doi.org/10.3390/met15070695 - 22 Jun 2025
Cited by 4 | Viewed by 1715
Abstract
This work investigates the role of friction in the numerical prediction of formability for ultra-thin aluminum sheets made of the EN AW 8006-O alloy. Nakazima-type hemispherical punch stretching tests were conducted under lubricated conditions to assess the influence of interface tribology on thickness [...] Read more.
This work investigates the role of friction in the numerical prediction of formability for ultra-thin aluminum sheets made of the EN AW 8006-O alloy. Nakazima-type hemispherical punch stretching tests were conducted under lubricated conditions to assess the influence of interface tribology on thickness distribution and failure behavior. The experimental activity included tensile testing for material parameter identification and coefficient of friction (COF) measurements according to ASTM D1894 to characterize interface friction. These parameters were then implemented into a finite element model developed in PAM-STAMP. The simulation results were compared with experimental thickness profiles, and showed good agreement when calibrated friction coefficients were used. The analysis highlights the sensitivity of sheet deformation to frictional conditions, and demonstrates that accurate tribological input significantly improves predictive accuracy. The proposed workflow offers a reliable and efficient methodology for simulating forming processes involving ultra-thin aluminum foils, with potential applications in the food packaging industry. Full article
(This article belongs to the Special Issue Advances in Lightweight Alloys, 2nd Edition)
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Review

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33 pages, 20199 KB  
Review
Composition Optimization in Alloy Design for Nickel-Based Single Crystal Superalloy: A Review
by Yu Zhou, Xinbao Zhao, Yunpeng Fan, Quanzhao Yue, Wanshun Xia, Qinghai Pan, Yuan Cheng, Weiqi Li, Yuefeng Gu and Ze Zhang
Metals 2025, 15(7), 793; https://doi.org/10.3390/met15070793 - 13 Jul 2025
Cited by 17 | Viewed by 7356
Abstract
This article presents a review of the composition optimization progress of nickel-based single crystal (SC) superalloy design in recent years in order to obtain better high-temperature performance for the development of the aviation industry. The influence of alloying elements on the creep resistance, [...] Read more.
This article presents a review of the composition optimization progress of nickel-based single crystal (SC) superalloy design in recent years in order to obtain better high-temperature performance for the development of the aviation industry. The influence of alloying elements on the creep resistance, microstructure characteristics, oxidation resistance, castability, density, and cost of superalloys is analyzed and discussed. In order to obtain better high-temperature performance, the content of refractory elements (Ta + Re + W + Mo) and Co was increased gradually. The addition of Ru was added in the fourth-generation nickel-based SC superalloy to stabilize the microstructures and suppress the precipitation of the topologically close-packed (TCP) phase. However, the content of the antioxidant element Cr significantly decreased, while the synergistic effect of Al, Cr, and Ta received more attention. Therefore, synergistic effects should also receive more attention to meet the practical needs of reducing the content of refractory elements to reduce costs and density in future single crystal alloy designs without compromising critical performance. Full article
(This article belongs to the Special Issue Advances in Lightweight Alloys, 2nd Edition)
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