This comprehensive review focuses on the most recent advances in electron backscatter diffraction (EBSD) methods in the context of materials science and includes a thorough evaluation of the sample preparation procedures unique to EBSD as well as a complete examination of the important operational parameters inherent in EBSD setups. This review highlights the importance of customizing EBSD parameters for precise microstructural imaging and enhancing understanding of material behavior. While some studies have explored grain boundary characterization, stored energy, and crystallographic orientation using EBSD, there is a clear need for more comprehensive investigations to fully leverage its capabilities. Additionally, there is a significant gap in understanding the optimal choice of the reference plane in EBSD analysis, indicating the necessity for further research to improve EBSD analyses’ accuracy and efficacy. The review seeks to present a detailed and contemporary viewpoint on the many applications, sample preparation techniques, and optimal operational considerations that jointly increase the adaptability and efficacy of EBSD in materials science research by relying on the relevant literature.

The proposed review demonstrates the effect of the surface modification process, specifically, deep rolling, on the material surface/near-surface properties of commercial steels. The present research examines the various process parameters involved in deep rolling and their effects on the material properties of AISI 1040 steel. Key parameters such as the rolling force, feed rate, number of passes, and roller geometry are analyzed in detail, considering their influence on residual stress distribution, surface hardness, and microstructural alterations. Additionally, the impact of deep rolling on the fatigue life, wear resistance, and corrosion behavior of AISI 1040 steel is discussed. Engineering components manufactured by AISI 1040 steel can perform better and last longer when deep rolling treatments are optimized with an understanding of how process variables and material responses interact. This review provides critical insights for researchers and practitioners interested in harnessing deep rolling techniques to enhance the mechanical strength and durability of steel components across diverse industrial settings. In summary, the valuable insights provided by this review pave the way for continued advancements in deep rolling techniques, ultimately contributing to the development of more durable, reliable, and high-performance steel components in diverse industrial applications. The establishment of generalized standardizations for the deep rolling process proves unfeasible because of the multitude of controlling parameters and their intricate interactions. Thus, specific optimization studies tailored to the material of interest are imperative for process standardization. The published literature on the characterization of surface and subsurface properties of deep-rolled AISI 1040 steel, as well as process parameter optimization, remains limited. Additionally, numerical, analytical, and statistical studies and the role of ANN are limited compared with experimental work on the deep rolling process.

The present work mainly focuses on a comparative study of the individual and combined effect of reinforcements on tensile strength and fracture surface analysis of Al6061 alloy and its composites during artificial aging. SiC and B₄C are the two reinforcements used in the present work for the preparation of Al6061 composites by the stir casting process, and the reinforcement percentage from 2, 4, and 6 wt.% varied. Both Al6061 alloy and its composites are solution-treated at 558 °C/2 h and artificially aged at 100 and 200 °C for different time intervals to achieve peak aging. The results show substantial improvement in ultimate tensile strength during low temperature aging at 100 °C. Approximately 80–110% increase in UTS value is observed in both individual and hybrid composites compared to Al6061 alloy. The mechanism of failure governing the tensile strength for both alloy and its composites is thoroughly analyzed and discussed using a scanning electron microscope. The morphology of crack propagation is also studied to determine the mechanism of failure. Al6061 alloy shows ductile failure due to coarser dimples. Al6061-SiC composites show particle-matrix interface cracking and shear failure. Al6061-B₄C composites show elongated dimple rupture mode of failure, whereas Al6061-SiC + B₄C hybrid composites fail due to nucleation growth and mixed fracture mode.

The present work focuses on the effect of multistage solution heat treatment (MSHT) and artificial aging on two-stage stir-cast LM4 + TiB₂ (1, 2, and 3 wt.%) composites on the mechanical properties as compared to as-cast and single-stage solution heat-treated (SSHT) composites. Two novel tests, viz. the confirmation hardness test and the chemical analysis test, were performed to ensure the soundness of the casting and uniform distribution of TiB₂ within the matrix. Samples subjected to MSHT + aging at 100–200 °C displayed the highest hardness and UTS values compared to as-cast and SSHT + aging at 100–200 °C samples. Compared to as-cast alloy, peak-aged samples of 1–3 wt.% (MSHT + aging at 100 °C), hardness values improved from 107–150%, and UTS values improved from 47–68%. The presence of metastable phases (θ′-Al₂Cu and θ″-Al₃Cu) and of hard TiB₂ particles are the reason for the improvement in the properties. Peak aged LM4 + 3 wt.% TiB₂ composite displayed the highest hardness of 175 VHN and UTS of 251 MPa. Fracture analysis of the LM4 alloy showed dimple rupture, and its composites revealed quasi-cleavage fracture. Based on the overall results, the inclusion of TiB₂, MSHT, and artificial aging treatment on the LM4 alloy significantly influenced the composites’ mechanical properties.

The present work reflects the effects of trace addition of copper (up to 1 wt.%) and zinc (0.5 wt.%) on the microstructure and hardness property of heat treated A356 (Al-7Si) alloy. Small amount of zinc and copper was introduced into A356 in both atomic form (alloy) and powder form (composite) and its age hardening behaviour were investigated. To enhance the wettability during composite fabrication and solid solution strengthening in alloys, a small quantity of magnesium (1 wt.%) was added. The main objective of this study is to introduce lower melting point zinc reinforcement into A356 matrix alloy by copper coating of zinc particles and then reinforcing it into A356 matrix. All stir cast specimens were subjected to T6 treatment by solutionizing at 520 °C for 2 h followed by 60 °C water quench and then aging at 100 and 200 °C to determine peak hardness value. Microstructure analysis showed that a minimum 1 wt.% copper was required to form Al₂Cu intermetallic phase during solidification resulting in finer grain structure with hardness improvement. Under as-cast conditions, a maximum hardness of 85 VHN was obtained in 1 wt.% copper reinforced composite. Under peak aged conditions, aging at 100 °C showed 116% hardness improvement in 1 wt.% Cu reinforced composite.