Research on pre-deformation influences on material properties in multistep hot forming is of important scientific interest. In this paper, hot tensile tests at 850 °C and a strain rate of 0.001 s⁻¹ were performed to study the microstructural evolution and mechanical properties of Ti-6Al-4V with pre-strains at 0.05, 0.1 and 0.15. The tensile test results showed that the specimen with 0.05 pre-strain exhibited higher flow stress and larger elongation. Additionally, increasing the pre-strain resulted in a decrease in ultimate tensile strength (UTS) and elongation (EL). The EBSD results showed that the main deformation mechanism of Ti-6Al-4V was high-angle grain boundary sliding. Pre-strain promoted dynamic recrystallization (DRX) by increasing the deformation substructure. The refinement of grains and the eradication of dislocations enhanced the deformability, resulting in an increase in flow stress.

The Helmholtz resonance acoustic metamaterial is an effective sound absorber in the field of noise reduction, especially in the low-frequency domain. To overcome the conflict between the number of Helmholtz resonators and the volume of the rear cavity for each chamber with a given front area of single-layer metamaterial, a novel acoustic metamaterial of interlayer parallel connection of multiple Helmholtz resonators (IPC–MHR) is proposed in this study. The developed IPC–MHR consists of several layers, and the Helmholtz resonators among different layers are connected in parallel. The sound absorption property of IPC–MHR is studied by finite element simulation and further optimized by particle swarm optimization algorithm, and it is validated by standing wave tube measurement with the sample fabricated by additive manufacturing. The average sound absorption coefficient in the discrete frequency band [200 Hz, 300 Hz] U [400 Hz, 600 Hz] U [800 Hz, 1250 Hz] is 0.7769 for the IPC–MHR with four layers. Through the optimization of the thickness of each layer, the average sound absorption coefficient in 250–750 Hz is up to 0.8068. Similarly, the optimized IPC–MHR with six layers obtains an average sound absorption coefficient of 0.8454 in 300–950 Hz, which exhibits an excellent sound absorption performance in the low-frequency range with a wide band. The IPC–MHR can be used to suppress obnoxious noise in practical applications.

The high-strength aluminum alloy 7B04 used in aircraft structures poses challenges in welding. In this study, 7075 aluminum alloy powder is used as an interlayer to strengthen the vacuum diffusion bonding (DB) joint of 7B04 aluminum alloy. Surface treatments with plasma activation before DB can effectively increase the bonding rate and lap shear strength (LSS) of the joint. The effects of DB temperature, pressure, and holding time on the joint LSS were analyzed by developing a quadratic regression model based on the response surface method (RSM). The model’s determination coefficient reached 99.52%, with a relative error of about 5%, making it suitable for 7B04 aluminum alloy DB process parameters optimization and joint performance prediction. Two sets of process parameters (505 °C-5.7 h-4.5 MPa and 515 °C-7.5 h-4.4 MPa) were acquired using the satisfaction function optimization method. Experimental results confirmed that the error between measured and predicted LSS is approximately 5%, and a higher LSS of 174 MPa was achieved at 515 °C-7.5 h-4.4 MPa.

Diffusion bonding (DB) of aluminum alloys faces significant technical challenges, requiring thorough surface preparation and precise control of process parameters. To enhance the joint quality of 7B04 aluminum alloy sheets, pure aluminum (Al) and 7075 aluminum alloy powders were used as interlayers. In the DB experiments, nano-sized Al powder and micro-sized 7075 powders with different particle sizes served as interlayer materials. Compared to DB without an interlayer, using powder interlayers substantially reduced the bonding temperature while improving overall joint performance, with deformation kept below 6%. The lap shear strength (LSS) of the bonded 7B04 joints was significantly higher when 45 μm and 75 μm 7075 powders were used, compared to the 5 μm 7075 powder. The joint with a 50 nm Al powder interlayer achieved a maximum LSS of up to 220 MPa and exhibited considerably higher microhardness. Additionally, the mixed Al/7075 powder interlayer effectively decreased voids at the joint interface, contributing to increased LSS.