Magnesium is the lightest structural metal, and alloying with lithium makes it even lighter. However, multi-phase Mg-Li alloys typically undergo rapid corrosion, and their strength decreases at room temperature due to natural age-softening. Here, we engineer a rapidly degrading dual-phase Mg-Li-Al alloy to be durable via friction stir processing followed by liquid CO₂ quenching. The best performing alloy has a low electrochemical degradation rate of 0.72 mg·cm⁻²· day⁻¹, and high specific strength of 209 kN·m·kg⁻¹. We attribute this electrochemical and mechanical durability to its microstructure, which consists of a refined grain size of approximately 2 µm and dense nanoprecipitates. This microstructure suppressed the formation of the detrimental AlLi phase, and an aluminium-rich protective surface layer also formed. This processing route might be useful for designing lightweight and durable engineering alloys.

Additive friction stir deposition (AFSD) is a novel solid-state additive manufacturing method developed on the principle of stirring friction. Benefits from its solid-phase properties, compared with traditional additive manufacturing based on melting–solidification cycles, AFSD solves the problems of porosity, cracks, and residual stress caused by the melting–solidification process, and has a significant improvement in efficiency. In AFSD, the interaction between feedstocks and high-speed rotating print heads suffers severe plastic deformation at high temperatures below the melting point, ending up in fine, equiaxed recrystallized grains. The above characteristics make components by AFSD show similar mechanical behaviors to the forged ones. This article reviews the development of AFSD technology, elaborates on the basic principles, compares the macroscopic formability and material flow behavior of AFSD processes using different types of feedstocks, summarizes the microstructure and mechanical properties obtained from the AFSD of alloys with different compositions, and finally provides an outlook on the development trends, opportunities, and challenges to the researchers and industrial fields concerning AFSD.

Magnesium alloys, noted for their substantial mechanical strength and exceptional biocompatibility, are increasingly being considered for use in biodegradable implants. However, their rapid degradation and significant hydrogen release have limited their applications in orthopaedics. In this study, a novel Mg-RE-Sr alloy was created by friction stir processing to modify its microstructure and enhance its degradation performance. Through microstructural characterization, the friction stir processing effectively refined the grains, accelerated the re-dissolution of precipitates, and ensured a uniform distribution of these phases. The processed alloy demonstrated improved comprehensive properties, with an in vitro corrosion rate of approximately 0.4 mm/y and increases in ultimate tensile strength and elongation by 37 % and 166 %, respectively. Notably, in vivo experiments involving a rat subcutaneous implantation model revealed a slower degradation rate of 0.09 mm/y and a uniform degradation process, basically achieving the requirements for ideal performance in orthopaedic applications. The superior degradation characteristics were attributed to the synergistic effect of attenuated galvanic corrosion and the formation of a dense Y(OH)₃/Y₂O₃ film induced by an exceptional microstructure with a highly solid-soluted matrix and uniformly refined precipitates. Meanwhile, the alloys exhibited excellent biocompatibility and did not cause undesirable inflammation or produce toxic degradation products. These improvements in biocompatibility and degradation characteristics indicate great promise for the use of this friction stir processed alloy in osteosynthesis systems in the clinical setting.

In conventional friction stir welding of magnesium alloys, a strong (0001) texture at the welded zone is inevitable, which deteriorates the joint mechanical properties. A novel method called ‘double-sided friction stir welding’ solved this problem by weakening the texture. However, the texture-weakening mechanism remains unclear. In this study, the mechanism of the texture weakening in double-sided friction stir welded Mg alloy was systematically analysed. The welding temperature and the material flow mode were revealed to control the (0001) texture randomisation simultaneously. The unique material flow at the mid-thickness layer caused by the double-sided friction stir welding was revealed to match the ‘beat phenomenon’ for the first time, which was revealed as the dominant mechanism for the (0001) texture randomisation.

Carbon nanotubes/2Al2 composites, due to their low density, high specific strength, and high elastic modulus, are representative lightweight structural materials for next-generation aerospace applications. Traditional processing methods are inefficient and have long production cycles, making them unsuitable for the demands of efficient, rapid, and intelligent manufacturing of complex structures. This article proposes the use of metal additive manufacturing technology to solve this problem. For the first time, a 22 mm high carbon nanotube/2Al2 composite was fabricated using additive friction stir deposition, and the changes in surface morphology, microstructure, mechanical properties, and corrosion resistance of the as-deposited composite were systematically studied. After additive manufacturing, the composite exhibited a continuous and defect-free, typical onion-like structure. The as-deposited microstructure consists of uniformly equiaxed grains with an average grain size of 1.23 μm to 1.62 μm and uniformly distributed Al₂Cu particles. The tensile strength and elongation of the as-deposited composite in both the transverse and processing directions are no less than 450 MPa and 15%, respectively, superior to those of the base material. After additive manufacturing, the as-deposited composite exhibited a corrosion current density of 0.19 μA cm⁻² in the transverse direction—only 4% of that of the base material. This enhanced corrosion resistance is attributed to the uniform distribution of precipitated phases achieved through additive manufacturing, which suppresses micro-galvanic corrosion, resulting in minimal, uniform corrosion. This study provides a research foundation and technical support for the additive manufacturing of aluminum-based composites.