Magnesium (Mg) alloys have emerged as highly sought-after alloys in aerospace, automotive, and biomedical engineering industries due to their low density and excellent mechanical properties. The addition of alloying elements plays a critical role in improving the performance of these Mg alloys, with rare-earth (RE) elements being especially helpful in improving mechanical properties, specifically strength and ductility. However, due to the higher cost and limited availability of RE elements, researchers are trying to explore non-rare-earth (non-RE) alternatives, such as aluminum, calcium, zinc, etc. These non-RE elements offer various advantages including cost effectiveness and enhanced manufacturability, but they may not always match the performance improvements of RE elements. This review critically examines and compares the effects of RE and non-RE alloying elements on the microstructural evolution, corrosion resistance, and strengthening implications of Mg alloys. Furthermore, it explores the recent advancements in alloy development and evaluates the trade-offs between RE and non-RE alloying elements, offering key insights into the optimal approaches for enhancing the performance of Mg alloys across various applications.

In the present study, the effect of annealing treatment on the room-temperature mechanical performance of AZ61, AZ61-0.5CaO and AZ61-1CaO was thoroughly investigated. The as-rolled samples were annealed at 400 °C for 1 h followed by furnace cooling. Microstructural characterization was carried out using optical microscopy (OM), scanning electron microscopy (SEM), transmission electron microscopy (TEM) and electron back-scattered diffraction (EBSD). Moreover, room-temperature uniaxial tensile tests were carried out on the non-annealed and annealed samples along the rolling direction at the strain rate of 10⁻³ s⁻¹. Microstructural analysis showed the presence of profuse $\left\{10\overline{1}2\right\}$ twinning in non-annealed samples and the twinning fraction was increased by the addition of CaO content. SEM showed the formation of precipitates in the AZ61-CaO alloys and TEM confirmed the precipitates to be (Mg, Al)₂Ca. The room-temperature tensile tests showed that the mechanical properties of AZ61 were slightly reduced by the addition of CaO, which was attributed to the higher local stress concentration due to the twin–twin interactions. Furthermore, the annealing treatment led to significant enhancement in the YS and UTS of AZ61-1CaO, which is related to the precipitation hardening induced by the intermetallic precipitates.

Lightweight magnesium alloys are gaining increasing attention as potential structural materials for automotive and aerospace applications due to their high specific strength and excellent recyclability. However, their formability and mechanical performance are often limited by strong basal texture and limited recrystallization during thermomechanical processing. In this context, the present study systematically investigates the effect of post-annealing treatment on the microstructural evolution, recrystallization behavior, and mechanical response of a hot-rolled Mg-3Al-1Zn-1Ca alloy. Detailed microstructural characterization revealed that Al₂Ca precipitates were uniformly distributed along grain boundaries in the as-received (AR) condition, where they contributed to significant pinning of boundary migration. Post-annealing treatment (350 °C, furnace cooling) resulted in non-uniform grain coarsening, driven by the interplay of precipitate pinning and differential stored strain energy, while also facilitating particle-stimulated nucleation (PSN) and recrystallization. Electron backscatter diffraction (EBSD) analysis confirmed a substantial increase in the fraction of high-angle grain boundaries and recrystallized grains in the heat-treated (HT) state, with kernel average misorientation (KAM) and grain orientation spread (GOS) analyses indicating pronounced recovery of lattice distortions. Mechanical testing demonstrated a significant decrease in yield strength (263 MPa to 187.4 MPa) and hardness (65.7 to 54.1 HV) due to dislocation annihilation and stress relaxation, while ultimate tensile strength remained nearly unchanged (~338 MPa) and ductility improved markedly (12.6% to 16.4%). These findings highlight the dual role of Al₂Ca precipitates in promoting recrystallization through PSN while simultaneously restricting excessive grain growth through Zener pinning.

The creep rupture life of 5Cr-0.5Mo steels used in high-temperature applications is significantly influenced by factors such as minor alloying elements, hardness, austenite grain size, non-metallic inclusions, service temperature, and applied stress. The relationship of these variables with the creep rupture life is quite complex. In this study, the creep rupture life of 5Cr-0.5Mo steel was predicted using various machine learning (ML) models. To achieve higher accuracy, various ML techniques, including random forest (RF), gradient boosting (GB), linear regression (LR), artificial neural network (ANN), AdaBoost (AB), and extreme gradient boosting (XGB), were applied with careful optimization of hidden parameters. Among these, the ANN-based model demonstrated superior performance, yielding high accuracy with minimal prediction errors for the test dataset (RMSE = 0.069, MAE = 0.053, MAPE = 0.014, and R² = 1). Additionally, we developed a user-friendly graphical user interface (GUI) for the ANN model, enabling users to predict and optimize creep rupture life. This tool helps materials scientists and industrialists prevent failures in high-temperature applications and design steel compositions with enhanced creep resistance.

Additive manufacturing (AM) of titanium alloys enables the production of complex, high-performance components, but the steep thermal gradients and rapid solidification involved make it challenging to control crystallographic texture and phase evolution. This review synthesizes the current understanding of how these thermal conditions influence grain morphology, texture intensity, and solid-state transformations in key alloys such as Ti-6Al-4V (Ti64), Ti-6Al-2Sn-4Zr-2Mo (Ti6242), Ti-5Al-5Mo-5V-3Cr (Ti5553), and metastable β-Ti systems processed by powder bed fusion-based processes (PBF) such as laser powder bed fusion (LPBF) and electron beam powder bed fusion (EBPBF/EBM). Emphasis is placed on mechanisms governing epitaxial columnar β-grain growth, α′ martensite formation, and the development of heterogeneous α/β distributions. The impact of processing variables on texture development and transformation kinetics is critically examined, alongside phase fractions. Across studies, AM-induced textures are consistently linked to mechanical anisotropy, with performance strongly dependent on build direction and alloy chemistry. Post-processing strategies, including tailored heat treatments and hot isostatic pressing (HIP), show clear potential to modify grain structure, reduce texture intensity, and stabilize desirable phase balances in titanium alloys. These insights highlight the emerging ability to deliberately engineer microstructures for reliable, application-specific properties in powder-based AM titanium alloys.