By choosing the density of particle as the design variables, a new implementation method of topology optimization is presented based on the Element-free Galerkin (EFG) method in this paper, in which the optimal objective is to minimize structural compliance. The advantage of using nodal density is that the displacement and density in the influence domain have the same approximation scheme, and the smoothness of the density field can be improved. Nodal density method presented can prevent the checkerboard from the mathematical model proposed. The topology optimal model based on EFG method under multiple loading cases and stress constraints is proposed, and the sensitivity analysis of optimal design is derived in detail. By using solid isotropic material with penalization (SIMP) method and optimality criteria (OC) method, an algorithm of topology optimization based on the EFG method is presented. The shortcoming of using nodal density can be overcome by introducing the penalty function method. Three topology optimal examples are solved successfully and test the model and algorithm proposed. The results obtained show that the checkerboard phenomenon arisen in topology optimization is not found, and the method proposed is not only effective in suppressing checkerboards but also has better convergence.

Based on end-quenching experiments combined with conductivity, hardness testing, and microstructural characterization, the quenching sensitivity of the mechanical and corrosion properties of 7475 aluminum alloy was investigated. The study revealed that as the quenching rate decreased, both the mechanical properties and exfoliation corrosion resistance exhibited increased quenching sensitivity. With the quenching rate decreasing from 31.9 °C/s to 2.5 °C/s, the conductivity increased by 4.1%IACS, the hardness decreased by 31%, the exfoliation corrosion grade transitioned from EC to ED, and the maximum exfoliation corrosion depth increased from 237 μm to 508 μm. As the quenching rate decreased, the η phase sequentially precipitated at recrystallized grain boundaries (RGBs), E phase particles, and subgrain boundaries (SGBs), while the T phase primarily precipitated on E phase particles. Furthermore, the significant precipitation of η and T phases led to a notable reduction in the quantity of age-precipitated phases, an increase in their size, and poor coherency with the matrix, resulting in decreased mechanical properties and a higher quenching sensitivity of the mechanical performance. Meanwhile, with the reduction in quenching rate, the size and spacing of grain boundary precipitated phases increased, the Zn and Mg contents of grain boundary precipitated phases increased, and the Precipitation Free Zone (PFZ) widened, leading to decreased exfoliation corrosion resistance and higher quenching sensitivity of the exfoliation corrosion performance.

The influence of grain structure and quenching rates on the exfoliation corrosion (EXCO) susceptibility of 7085 alloy was studied using immersion tests, optical microscopy (OM), scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and scanning transmission electron microscopy (STEM). The results show that as the cooling rate decreases from 1048 °C/min to 129 °C/min; the size of grain boundary precipitates (GBPs); the width of precipitate-free zones (PFZ); and the content of Zn, Mg, and Cu in GBPs rise, leading to an increase in EXCO depth and consequently higher EXCO susceptibility. Meanwhile, there is a linear relationship between the average corrosion depth and the logarithm of the cooling rate. Corrosion cracks initiate at the grain boundaries (GBs) and primarily propagate along the HAGBs. In the bar grain (BG) sample at lower cooling rates, crack propagation along the sub-grain boundaries (SGBs) was observed. Compared to equiaxed grain (EG) samples, the elongated grain samples exhibit larger GBPs, a wider PFZ, and minor compositional differences in the GBPs, resulting in higher EXCO susceptibility.

Through isothermal hot compression experiments at various strain rates and temperatures, the thermal deformation behavior of Zn-2.0Cu-0.15Ti alloy is investigated. The Arrhenius-type model is utilized to forecast flow stress behavior. Results show that the Arrhenius-type model accurately reflects the flow behavior in the entire processing region. The dynamic material model (DMM) reveals that the optimal processing region for the hot processing of Zn-2.0Cu-0.15Ti alloy has a maximum efficiency of about 35%, in the temperatures range (493–543 K) and a strain rate range (0.01–0.1 s⁻¹). Microstructure analysis demonstrates that the primary dynamic softening mechanism of Zn-2.0Cu-0.15Ti alloy after hot compression is significantly influenced by temperature and strain rate. At low temperature (423 K) and low strain rate (0.1 s⁻¹), the interaction of dislocations is the primary mechanism for the softening Zn-2.0Cu-0.15Ti alloys. At a strain rate of 1 s⁻¹, the primary mechanism changes to continuous dynamic recrystallization (CDRX). Discontinuous dynamic recrystallization (DDRX) occurs when Zn-2.0Cu-0.15Ti alloy is deformed under the conditions of 523 K/0.1 s⁻¹, while twinning dynamic recrystallization (TDRX) and CDRX are observed when the strain rate is 10 s⁻¹.

The Portevin–Le Chatelier effect of Cu–2.0Be alloy was investigated using hot isothermal compression at varying strain rates (0.01–10 s⁻¹) and temperature (903–1063 K). An Arrhenius-type constitutive equation was developed, and the average activation was determined. Both strain-rate-sensitive and temperature-sensitive serrations were identified. The stress–strain curve exhibited three types of serrations: type A at high strain rates, type B (mixed A + B) at medium strain rates, and type C at low strain rates. The serration mechanism is mainly affected by the interaction between the velocity of solute atom diffusion and movable dislocations. As the strain rate increases, the dislocations outpace the diffusion speed of the solute atoms, limiting their ability to effectively pin the dislocations, resulting in lower dislocation density and serration amplitude. Moreover, the dynamic phase transformation triggers the formation of nanoscale dispersive β phases, which impede dislocation and cause a rapid increase in the effective stress required for unpinning, leading to the formation of mixed A + B serrations at 1 s⁻¹.