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Metals
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Special and Short Processes of Aluminum Alloys
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Special and Short Processes of Aluminum Alloys

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Corrosion and Protection".

Deadline for manuscript submissions: 30 June 2025 | Viewed by 2154

Special Issue Editors

Dr. Cong Xu

E-Mail Website
Guest Editor
School of Materials Science and Engineering, Zhengzhou University, Zhengzhou, China
Interests: high-performance aluminum alloy; metal matrix composite
Prof. Dr. Yufeng Sun

E-Mail Website
Guest Editor
School of Materials Science and Engineering, Zhengzhou University, Zhengzhou, China
Interests: friction stir welding and processing; ultrafine grain structured materials; degradable Mg alloy biomaterials
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The global aluminum market was valued at USD 229.85 billion in 2023 and is projected to grow from USD 243.89 billion in 2024 to USD 393.70 billion by 2032. Aluminum and its alloys are silvery-white, non-magnetic, and ductile metals that play a critical role in the automotive, aerospace, building, and other industries. Moreover, the manufacturing process significantly influences the microstructures and properties of aluminum alloys. Therefore, the development of new aerospace aluminum alloys and automotive lightweighting is crucial.

With the increasingly serious environmental and energy crisis, some aluminum alloys that have undergone special and short processes have been gradually employed to product manufacturing in recent decades. This has occurred due to their characteristic benefits, including low investment costs, low energy consumption, and high efficiency. However, until now, not many research studies have been published on the special and short processes of aluminum alloys compared to traditional processing routes.

This Special Issue of Metals focuses on the short and special processes of aluminum alloys. The papers presented in this Special Issue provide an account of 2024’s scientific and technological state of the art special and short processes of aluminum alloys (see the Keywords/Topics section below). Your contributions to this compilation will be highly valuable and appreciated. We invite you to contribute research studies on the effects of short and special processes in relation to the microstructures and various properties of aluminum alloys.

Dr. Cong Xu
Prof. Dr. Yufeng Sun
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 100 words) can be sent to the Editorial Office for announcement on this website.

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. 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
  • short process
  • special process
  • solidification
  • continuous casting
  • roll casting
  • deformation
  • welding
  • heat treatment
  • microstructure
  • strength
  • ductility
  • corrosion resistance

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (4 papers)

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Research

13 pages, 8991 KiB  
Article
Effect of In Situ Al Roll Coating on Strip Surface Quality in Traditional Twin-Roll Casting of Aluminum Alloys
by Han-Gyoung Cho, Young Do Kim and Min-Seok Kim
Metals 2025, 15(4), 377; https://doi.org/10.3390/met15040377 - 28 Mar 2025
Viewed by 218
Abstract
The twin-roll casting (TRC) process is widely used in the aluminum industry due to its cost efficiency and continuous production capability. However, maintaining consistently high surface quality remains challenging due to complex heat transfer behavior at the roll/strip interface. This study examines the [...] Read more.
The twin-roll casting (TRC) process is widely used in the aluminum industry due to its cost efficiency and continuous production capability. However, maintaining consistently high surface quality remains challenging due to complex heat transfer behavior at the roll/strip interface. This study examines the critical influence of roll surface conditions, especially the formation of an Al coating layer, on solidification behavior and resulting strip quality in the TRC of an Al-5Mg alloy. Experimental results demonstrated that casting without an Al coating layer led to surface defects such as hot tears and porosity due to insufficient cooling. In contrast, strips produced with a stable Al coating layer exhibited excellent surface quality with no surface defects. Numerical simulations further indicated that a stable Al coating enhanced the interfacial heat transfer coefficient (up to 30,000 W/m2K), ensuring effective cooling and complete solidification before the strip exited the roll nip. Moreover, simulations validated the feasibility of using steel rolls in industrial applications, provided the coating layer was consistently maintained. This research highlights the significance of roll surface control in improving TRC product quality. Full article
(This article belongs to the Special Issue Special and Short Processes of Aluminum Alloys)
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15 pages, 8238 KiB  
Article
Effect of Pre-Deformation on the Microstructure and Precipitation Behavior of Spray-Formed 7xxx Series Aluminum Alloys
by Huiying Hou, Lei Zhang, Shuohao Xing, Hongchao Zhai, Shule Xia, Long Zhai, Zhijie Wang and Sha Liu
Metals 2025, 15(4), 365; https://doi.org/10.3390/met15040365 - 26 Mar 2025
Viewed by 189
Abstract
This study investigates the effect of pre-deformation on the microstructure and precipitation behavior of spray-formed 7xxx series aluminum alloys. Pre-deformation introduces a high density of dislocations, increasing the proportion of low-angle grain boundaries from 40% to 66%. After solution treatment at 580 °C, [...] Read more.
This study investigates the effect of pre-deformation on the microstructure and precipitation behavior of spray-formed 7xxx series aluminum alloys. Pre-deformation introduces a high density of dislocations, increasing the proportion of low-angle grain boundaries from 40% to 66%. After solution treatment at 580 °C, grain size significantly increases, ranging from 35 µm to 315 µm, with a higher proportion of larger grains observed in pre-deformed samples. Subsequent aging treatment refines the microstructure, resulting in grain sizes between 30 µm and 270 µm, and leads to a more uniform precipitate distribution. Full article
(This article belongs to the Special Issue Special and Short Processes of Aluminum Alloys)
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13 pages, 6400 KiB  
Article
Optimization of Electrical Conductivity and Hardness in Al-1Si Alloy Through Mg/Fe Alloying and Heat Treatment
by Xiaoli Cui, Houyun Liu, Yan Wang, Chao Lu, Wenqing Shi and Di Tie
Metals 2025, 15(3), 317; https://doi.org/10.3390/met15030317 - 14 Mar 2025
Viewed by 364
Abstract
In this study, a new kind of the Al-1Si-0.6Mg-0.2Fe alloy was fabricated by Mg, Fe alloying treatment and the influence mechanism of Mg, Fe on electrical conductivity (EC) and Vickers hardness (HV) of the Al-1Si alloy was analyzed by the combination of experiments [...] Read more.
In this study, a new kind of the Al-1Si-0.6Mg-0.2Fe alloy was fabricated by Mg, Fe alloying treatment and the influence mechanism of Mg, Fe on electrical conductivity (EC) and Vickers hardness (HV) of the Al-1Si alloy was analyzed by the combination of experiments and simulations. Results showed that during the solidification process, intermediate phase Al8FeMg3Si6 formed which can inhibit the growth of needle-like AlFeSi phase, resulting in a more refined distribution of AlFeSi particles and this is helpful to improve EC and HV simultaneously. According to the simulation results, Al-1Si-0.6Mg-0.2Fe generated the most Al8FeMg3Si6 and the corresponding EC and HV reached 48.5% IACS and 62.9 HV, respectively. Furthermore, during heat treatment process, AlFeSi can promote the nucleation of Mg2Si, reducing the elemental solution of Mg and Si. With 550 °C/2 h + 210 °C/24 h heat treatment, on the one hand, oversized needle-shaped AlFeSi fused to smaller particles and distributed more uniformly. On the other hand, more solid solution Si and Mg precipitated with form of Mg2Si. Finally, the EC and HV of Al-1Si-0.6Mg-0.2Fe improved to 54.5% IACS and 79.8 HV, achieving the simultaneous optimization of EC and HV. This can provide theoretical guidance for the preparation of high strength and high conductivity aluminum alloy. Full article
(This article belongs to the Special Issue Special and Short Processes of Aluminum Alloys)
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19 pages, 17830 KiB  
Article
Influence of Partial Er Substitution for Sc on the Microstructure, Mechanical Properties and Corrosion Resistance of Short-Processed Al-4.7Mg-0.6Mn-0.3Zr-0.3Sc Sheets
by Guangxi Lu, Yabo Liang, Cong Xu, Wenfei Rao, Yaodong Xue, Longfei Li, Li Zhang and Shaokang Guan
Metals 2024, 14(9), 1013; https://doi.org/10.3390/met14091013 - 5 Sep 2024
Viewed by 952
Abstract
Standard AA5083 (ZSE000), AA5083 modified with 0.3 wt.% Zr and 0.3wt.% Sc (ZSE330) and AA5083 modified with 0.3 wt.% Zr, 0.2wt.% Sc and 0.1wt.%Er(ZSE321) sheets were fabricated through a short process (including a simulated twin-belt continuous casting, subsequent direct rolling, intermediate annealing, cold [...] Read more.
Standard AA5083 (ZSE000), AA5083 modified with 0.3 wt.% Zr and 0.3wt.% Sc (ZSE330) and AA5083 modified with 0.3 wt.% Zr, 0.2wt.% Sc and 0.1wt.%Er(ZSE321) sheets were fabricated through a short process (including a simulated twin-belt continuous casting, subsequent direct rolling, intermediate annealing, cold rolling and stress-relief annealing) to systematically investigate the influence of partially substituting Er for Sc on the microstructure, mechanical properties and corrosion resistance of short-processed Al-4.7Mg-0.6Mn-0.3Zr-0.3Sc sheets. The results show that ZSE321 presents the optimal tensile properties (UTS: 541 MPa; 0.2%PS: 469 MPa and EF:7.7%) among the three experimental sheets. This is attributed to significant grain refinement, the inhibition of the recrystallization and promotion on the precipitation of Al3(Sc, Zr, Er) nanoparticles. Furthermore, the corrosion properties of the experimental sheets were also explored in this study, and the short-processed ZSE321 sheet presents the optimum corrosion resistance. Full article
(This article belongs to the Special Issue Special and Short Processes of Aluminum Alloys)
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