As one of the lightest structural metals, the application breadth of aluminum alloys is, to some extent, constrained by their relatively low wear resistance and hardness. However, laser cladding technology, with its low dilution rate, compact structure, excellent coating-to-substrate bonding, and environmental advantages, can significantly enhance the surface hardness and wear resistance of aluminum alloys, thus proving to be an effective surface modification strategy. This review focuses on the topic of surface laser cladding materials for aluminum alloys, detailing the application background, process, microstructure, hardness, wear resistance, and corrosion resistance of six types of coatings, namely Al-based, Ni-based, Fe-based, ceramic-based, amorphous glass, and high-entropy alloys. Each coating type’s characteristics are summarized, providing theoretical references for designing and selecting laser cladding coatings for aluminum alloy surfaces. Furthermore, a prediction and outlook for the future development of laser cladding on the surface of aluminum alloys is also presented.

Metallic three-dimensional lattice structures exhibit many favorable mechanical properties including high specific strength, high mechanical efficiency and superior energy absorption capability, being prospective in a variety of engineering fields such as light aerospace and transportation structures as well as impact protection apparatus. In order to further compare the mechanical properties and better understand the energy absorption characteristics of metal lattice structures, enhanced pyramidal lattice structures of three strut materials was prepared by 3D printing combined with investment casting and direct metal additive manufacturing. The compressive behavior and energy absorption property are theoretically analyzed by finite element simulation and verified by experiments. It is shown that the manufacturing method of 3D printing combined with investment casting eliminates stress fluctuations in plateau stages. The relatively ideal structure is given by examination of stress–strain behavior of lattice structures with varied parameters. Moreover, the theoretical equation of compressive strength is established that can predicts equivalent modulus and absorbed energy of lattice structures.

This study investigates the structure and corrosion behavior of the Al_0.8CrFeCoNiCu_0.5 high-entropy alloy prepared using non-consumable vacuum arc melting. XRD analysis identified BCC1 and BCC2 phases corresponding to (Fe-Cr) and Al-Ni, respectively, while the FCC phase aligned with Cu. SEM and EBSD observations confirmed an equiaxed grain structure with fishbone-like morphology at grain boundaries and modulated structures within the grains. The alloy exhibited minimal residual stress and strain. The alloy demonstrated a preferred orientation of grain growth along the direction. Electrochemical testing in a 3.5% NaCl solution revealed a corrosion potential of −0.332 V and a corrosion current density of 2.61 × 10⁻⁶ A/cm². The intergranular corrosion regions exhibited significant depletion of Al and Cu elements, with the corrosion products primarily consisting of Al and Cu. Al and Cu elements are susceptible to corrosion. The wear scar width of Al_0.8CrFeCoNiCu_0.5 high-entropy alloy is 1.65 mm, which is less than 45# steel, and high-entropy alloy has more excellent wear resistance. Given its unique attributes, this high-entropy alloy could find potential applications in high-end manufacturing industries such as the aerospace engineering, the defense industry, energy production, and chemical processing where high corrosion resistance and wear resilience are crucial.

In this study, the formation and crystallization of the Al₇₀Fe_12.5V_12.5Nb₅ amorphous alloys has been investigated. The addition of Nb enhances the supercooled liquid region and glass forming ability of the Al-Fe-V amorphous alloys. The Al₇₀Fe_12.5V_12.5Nb₅ amorphous alloy exhibits two distinct crystallization steps and a large supercooled liquid region at more than 100 K. Kissinger and Ozawa analyses showed that the two activation energies for crystallization (E_x) were estimated to be 366.3 ± 23.9 and 380.5 ± 23.9 kJ/mol. Large supercooled liquid regions are expected to gain an application field of Al-based amorphous alloys.

The Al₇₀Fe_12.5V_12.5Ni₅, Al₇₀Fe_12.5V_12.5Zr₅ and Al₇₀Fe_12.5V_12.5Nb₅ alloys were prepared via mechanical alloying. The influence of Zr, Nb or Ni addition on the glass-forming ability of Al-Fe-V amorphous alloys have been investigated. The structure of Al₇₀Fe_12.5V_12.5Ni₅ was amorphous and Al₇₀Fe_12.5V_12.5Zr₅ was not completely amorphous by transmission electron microscopy, selected area electron diffraction and differential scanning calorimetry. Different criteria were used to evaluate the influence of the addition of alloy elements on the Glass-forming ability. The Al₇₀Fe_12.5V_12.5Ni₅ amorphous alloys exhibits higher glass-forming ability and activation energies of crystallization. Comparison of the effective atomic size ratio and mixture enthalpy on the glass-forming ability of these amorphous alloys demonstrates that the effective atomic size ratio value becomes more significant than the values of mixture enthalpy.