Complex concentrated alloys (CCAs) are structural and functional materials of the future with excellent mechanical, physical, and chemical properties. Due to the equiatomic compositions of these alloys, cost can hinder scalability. Thus, the development of CCA-based coatings is critical for low-cost applications. The application of cold spray technology to CCAs is in its infancy with emphasis on transition elements of the periodic table. Current CCA-based cold spray coating systems showed better adhesion, cohesion, and mechanical properties than conventional one-principal element-based alloys. Comprehensive mechanical behavior, microstructural evolution, deformation, and cracking of cold spray CC-based coatings on the same and different substrates are reviewed. Techniques such as analytical models, finite element analysis, and molecular dynamic simulations are reviewed. The implications of the core effects (high configurational entropy and enthalpy of mixing, sluggish diffusion, severe lattice distortion, and cocktail behavior) and interfacial nanoscale oxides on the structural integrity of cold spray CCA-based coatings are discussed. The mechanisms of adiabatic heating, jetting, and mechanical interlocking, characteristics of cold spray, and areas for future research are highlighted.

An overview of welding methods and process parameters and its effects on mechanical behaviour and structural integrity of magnesium and its alloys are discussed. These alloys are less dense and beneficial structural alloys for improved energy efficiency, eco-friendliness and driver of circular economic model for sustainable design and innovative ecosystem. While the application of Mg-alloys is projected to increase, understanding the mechanical behaviour and structural integrity of welded joints are critical. Thus, fusion and solid-state welding processes of these alloys are discussed with emphasis on mechanical characterization. Laser welding is the most effective fusion welding technique for most Mg alloys whereas, the predominant solid-state method is friction stir welding. The importance of process variables such as heat inputs, welding velocity (speed) and post weld treatments on the microstructural evolution, on mechanical and physical properties of the distinct zones of the weld joints are described. The weldment is the most susceptible to failure due to phase transformation, defects such as microporosity and relatively coarse grain sizes after solidification. The implication of the design of quality weld joints of Mg alloys are explored with areas for future research directions briefly discussed.

Due to their excellent biocompatibility, titanium alloys are the preferred materials for manufacturing bioimplants. Low‐cost titanium alloys have been developed as cheaper and less toxic alternatives for Ti–6Al–4V in the biomedical industry, but their suitability for diabetes patients is yet to be evaluated. With the growing number of diabetes patients globally, this research investigated the corrosion performance of low‐cost Ti–3Fe, Ti–4.5Al–1V–3Fe, and Ti–6Al–1V–3Fe alloys in 0.9 wt.% sodium chloride solution and glucose‐containing Hanks balanced salt solution (HBSS) compared with Ti–6Al–4V. Glucose was added to simulate the body fluids of patients with prediabetic and diabetic conditions. Open circuit potential and potentiodynamic polarization tests were performed. The results reveal that Ti–4.5Al–1V–3Fe and Ti–6Al–1V–3Fe alloys show superior corrosion resistance compared with the other alloys in the glucose‐containing solutions, as they had the lowest corrosion rate and higher corrosion potential. Consequently, these alloys hold promise as effective implants, particularly for people living with diabetes.

Thermo-mechanical processing of refractory high entropy alloys (RHEAs) at high temperatures is very important. It is an effective method of modifying the microstructure, properties, and shaping into final components after casting. Using the Scopus database, 57 articles relating to the hot deformation of refractory high entropy alloys were extracted from 2011 to 2022. Despite the limited number of articles on hot deformation of RHEAs, it is important to find out if the dominant softening mechanisms reported in other metallic alloys are evident. This is the main impetus for this study since the hot deformation behavior has not been comprehensively studied. All the probable mechanisms influencing deformation in metallic alloys, such as work hardening, dynamic recrystallization, and dynamic recovery, have also been observed in RHEAs. The bulging phenomenon, serrated grain boundaries, and necklace-like structures reported in metallic alloys have also been detected in hot deformed RHEAs. Unsafe deformation behavior such as cracks that have been reported in metallic alloys, have also been observed in RHEAs. This review has provided a comprehensive study on the hot working processes of RHEAs and highlighted critical gaps for future research direction with some suggested limitations.

Additive manufacturing (AM) technologies and advances made globally in medicine, construction, aerospace, and energy sectors are discussed. The paper further explores the current state of AM innovation and development landscape in Africa as a late comer to this area of smart manufacturing. Peer-reviewed and published literature were retrieved from Scopus database from 2005 to 2021 and analysed. In Africa, out of 500 published articles, South Africa has the highest research throughput, whereas about two-thirds of the continent is not actively participating in this burgeoning field. The main AM techniques most widely used are selective laser melting, fused deposition modelling, and direct energy deposition. Globally, there is an interplay of computational (machine learning and mechanistic models) and experimental approaches to understanding the physical metallurgy of AM techniques and processes. Though this trend is consistent with global practices, Africa lags the world in AM technologies, a niche that could leapfrog the manufacturing sector. Thus, Africa need to foster collaborative partnership within and globally to become an active global player in this industry.