Titanium alloys exhibit exceptional strength-to-density ratios, high hardness, and outstanding resistance to elevated temperatures, making them indispensable structural materials in aerospace engineering, marine construction, and biomedical applications. In aerospace systems specifically, fatigue failure represents the predominant failure mode for titanium alloy components. This review systematically examines prevalent surface treatment techniques for titanium alloys—including shot peening, ultrasonic rolling treatment, hot isostatic pressing (HIP), physical vapor deposition (PVD), micro-arc oxidation (MAO), and thermal spray processes—and critically evaluates their respective effects on fatigue performance. The underlying mechanisms of each technique are concisely outlined, with emphasis on stress state evolution, near-surface microstructural refinement, and interfacial integrity. Building upon the characteristic surface-dominated fatigue fracture behavior of titanium alloys, this work focuses on how coating composition, architecture (e.g., graded, multilayer, or nanocomposite designs), and interfacial bonding strength govern fatigue resistance. A unified analysis is presented on the distinct yet complementary roles of substrate deformation strengthening (e.g., residual compression, grain refinement) and coating-mediated protection (e.g., barrier function, crack deflection, stress redistribution) during fatigue crack initiation and propagation. Key determinants of fatigue performance, including residual stress distribution, coating/substrate adhesion, thermal mismatch, and environmental degradation susceptibility, are rigorously assessed. Finally, emerging research frontiers are identified, including intelligent process–structure–property mapping, in situ monitoring of fatigue damage at coated interfaces, and design of multifunctional gradient coatings that synergistically enhance strength, wear resistance, and fatigue endurance of titanium alloy components.

This study investigates the effect of cathodic voltage on the thickness, morphology, composition, phase structure, adhesion, and elevated-temperature oxidation resistance of the micro-arc oxidation (MAO) ceramic coatings on Ti65 alloy. Coatings were fabricated via MAO under cathodic voltages of 50 V, 100 V, 150 V, and 200 V. Results indicate that the coatings primarily consist of rutile TiO₂ (R-TiO₂), anatase TiO₂ (A-TiO₂), and amorphous SiO₂. The thickness of the MAO coatings increased with rising cathodic voltage, while the surface porosity and average pore size of the coatings were first decreased and then increased with the increase in cathodic voltage. Excellent coating adhesion to the substrate was confirmed by 50 thermal shock cycles between 700 °C and room temperature. Cyclic oxidation tests at 750 °C for 100 h demonstrated that all MAO coatings significantly enhanced elevated-temperature oxidation resistance compared to the bare Ti65 substrate. Notably, the coating produced at 100 V exhibited the lowest oxidation weight gain (0.50 mg/cm²), amounting to only one-third of the substrate’s gain. The effect of the cathodic voltage on the high-temperature oxidation performance of the MAO coatings was systematically analyzed.

Titanium alloys are irreplaceable in aerospace, biomedical and marine industries due to their low density, high specific strength and excellent biocompatibility. Conventional manufacturing methods suffer from low material utilization and difficulty in fabricating complex components, while additive manufacturing (AM) realizes near-net-shape forming of customized structures but introduces unique non-equilibrium microstructures and defects, which significantly alter the corrosion behavior and limit the long-term service reliability of additively manufactured (AMed) titanium alloys. This work systematically analyzes the corrosion behavior of titanium alloys fabricated by four mainstream AM processes: LPBF (laser powder bed fusion)/SLM (selective laser melting), EBM (electron beam melting), DED (directed energy deposition) and WAAM (wire arc additive manufacturing). It quantitatively summarizes the key electrochemical parameters and discusses the regulatory effects of matrix composition, post-treatment and service environment on their corrosion behaviors. The universal corrosion mechanisms—namely, passive film breakdown, micro-galvanic corrosion, and defect-induced localized corrosion—as well as process-specific corrosion mechanisms inherent to AMed titanium alloys are systematically elucidated. This study offers theoretical foundations for optimizing corrosion resistance and ensuring the reliable engineering implementation of AMed titanium alloys.

This work provides a comprehensive review of the development and current research status of micro-arc oxidation (MAO) coatings on 6061 aluminum alloy. It presents research findings on the enhancement of wear resistance, corrosion resistance, and other functional properties (e.g., hydrophobicity, thermal control performance, and electrical insulation) using three main strategies: insitu growth via electrolyte composition modification or electrical parameter adjustment, incorporation of nanoparticles into the electrolyte, and hybrid processes combining MAO with other surface treatment techniques (e.g., pre-/post-treatments). The performance of coatings obtained under different strategies is summarized, and a prospective outlook on future development trends in this field is offered.

Titanium alloys are widely used for implants, yet corrosion, bacterial colonization and incomplete osseointegration remain important causes of interfacial failure. This review critically analyzes major biomedical functional coating fabrication techniques employed to enhance the surface properties of titanium alloys, including micro-arc oxidation, anodic oxidation, magnetron sputtering, electrochemical deposition, electrophoretic deposition, plasma spraying, physical vapor deposition, plasma immersion ion implantation, laser surface treatment, and hybrid (composite) approaches. For each method, key operational principles, structural and functional characteristics, performance advantages and limitations, and representative application domains are critically analyzed. Across these routes, biological performance depends on coating continuity, pore or nanotube geometry, interfacial bonding, phase composition and ion release. Calcium- and phosphorus-rich oxides and hydroxyapatite deposits generally promote cell adhesion, proliferation, alkaline phosphatase activity, mineralization and osteogenic differentiation. Dense oxide, nitride, tantalum and carbon-based films strengthen corrosion barriers, whereas Mn, Zn, Cu and Ag containing surfaces can inhibit bacterial adhesion and biofilm formation. Excessive ion release, however, may compromise cytocompatibility. Reported outcomes also vary with test medium, exposure time, bacterial strain and cell model. Standardized quantitative endpoints and longer-term corrosion, biofilm and osseointegration studies are required to guide clinically reliable multifunctional coatings.

Aluminum alloy is a lightweight, high-strength material based on aluminum matrix with the addition of elements such as copper, magnesium, silicon, zinc, manganese, or lithium. Featuring low density, high specific strength, excellent formability, and outstanding corrosion resistance, it is widely applied in the fields of aerospace, rail transit, automotive lightweighting, and additive manufacturing. In the aerospace sector, fatigue failure constitutes the primary failure mode of load-bearing components. This paper reviews the influence mechanisms of various strengthening technologies, namely shot peening (SP), laser shock processing (LSP), physical vapor deposition (PVD), micro-arc oxidation (MAO), anodic oxidation (ANO), additive manufacturing, casting, extrusion, and heat treatment, on the fatigue properties of aluminum alloys; analyzes the regulatory effects of process principles, coating compositions, and microstructures (grains, phase composition, and interfacial bonding) on crack initiation and propagation; discusses the synergistic effect between plastic deformation strengthening and coating functionality; summarizes the key material and process factors affecting the fatigue life of aluminum alloys; and finally prospects the technical development trends driven by high-reliability service requirements.