To achieve a further reduction in weight of titanium alloys and to satisfy the increasing demand of energy-saving for aerospace and automotive applications, a graphene oxide nanosheet-reinforced Ti6Al4V (GO/TC4) composite was successfully fabricated using spark plasma sintering (SPS). Contrary to the Widmanstätten microstructure of a monolithic TC4 sample, the microstructure of the composites displayed a typical basket-weave structure in virtue of the introduced residual tensile stress generated from the mismatch of coefficients of thermal expansion (CTE) between GO and TC4 during the phase transformation. Meanwhile, the in situ-formed TiC nanolayer and diffusion layer were identified at the GO–TC4 interface, which is expected to endow a stronger interfacial bonding. As compared with the TC4 sample, the TC4 composite with the addition of 0.27 wt.% GO exhibited a 0.2% yield strength of 921.8 MPa, an ultimate tensile strength of 1040.1 MPa, and an elongation of 5.3%, displaying a better balance of strength and ductility than that of the composite with a higher GO addition (0.54 wt.%). The synergetic strengthening mechanisms such as Orowan strengthening, enhanced dislocation density strengthening, and load transfer were confirmed. Among them, load transfer contributed greatly to the strength of the composites due to improved interfacial bonding between the GO fillers and TC4 matrix.

In recent years, research on hydroxyapatite (HA) coatings has been driven by the demands of clinical applications. However, the intrinsic brittleness of HA limits its potential in the use for the load-bearing implant. To improve mechanical properties of the HA coating itself, a HA composite coating reinforced with hexagonal boron nitride nanoplatelets (BNNP) was fabricated using plasma spray, and its scratch behavior was investigated in this research. Typical brittle fractures such as microcracks both in and beyond the residual groove and material chipping were observed in the HA coating, while stronger and tougher BNNP/HA coatings exhibited a dominant role in protecting them from scratch damage through resisting plastic deformation and brittle microfracturing. Moreover, easier grain sliding within a splat and splat sliding at the splat boundaries due to the presence of BNNPs, and the nature porosity at different length scales of the as-sprayed HA composite coatings would provide significant self-lubricating effects to reduce the lateral force during scratching and alleviate the contact damage. Therefore, the addition of BNNPs renders HA coating with low scratch friction and enhanced tolerance to surface damage, which is naturally beneficial for the long-term durability and reliability of the implants.

The nanoscale plasticity phenomena in zirconia-toughened alumina (ZTA) ceramics with yttria-stabilized zirconia (YSZ) addition of 10% and 30% fabricated by additive manufacturing based on a stereolithography technique were explored in detail by nanoindentation and scanning electron microscopy. It was demonstrated that the initiation of nanoscale plasticity was attributed to the combined contributions from the generation of nanoscale shear deformation bands and localized microcracking at the indentations. Such localized plastic behavior underneath the nanoindenter was interpreted by maximum shear stress analysis. The response of the phase boundary during indentation was emphasized through crack propagation paths, and optimization of alumina–YSZ adaptation through component design and SL processing was expected.

Multi-layer graphenes (MLGs) reinforced Cu matrix composites were fabricated using spark plasma sintering in this research. Microstructure observation indicated that MLGs homogeneously disperse in the matrix to result in grain refinement. Instrumented spherical micro-indentation tests were conducted to evaluate micro-mechanical properties of the composites, and the elastic modulus and indentation yield strength of the 1.5 wt.% MLG/Cu composite increase up to ~ 36% and ~ 41% than those of the unreinforced Cu, respectively. Grain refinement, the enhanced dislocation density (EDD) due to the thermal expansion mismatch between Cu matrix and MLGs and Orowan are thought to be the main strengthening mechanisms in this research.

Metal Digital light processing (MDLP) offers high resolution and excellent surface quality, but the final properties of printed parts are highly dependent on post-processing. In this study, the effects of debinding, decarburization, and sintering on the shape fidelity, microstructure, and mechanical properties of MDLP-fabricated 316L stainless steel were systematically investigated. The optimal post-processing route consisted of debinding in an inert atmosphere, decarburization in air within 400–600 °C, and sintering at 1370 °C for 4 h under flowing nitrogen. Under these conditions, the sintered parts achieved a relative density of 98.03 ± 0.23%, hardness of 380.63 ± 9.15 HV, elastic modulus of 213.47 ± 5.5 GPa, tensile strength of 519.7 ± 22 MPa, and elongation at fracture of 76.8 ± 9.3%. Microstructural analysis showed that increasing the sintering temperature reduced porosity and smoothed the morphology of Cr-rich oxygen-containing second phase regions, thereby alleviating stress concentration and improving mechanical properties. This study provides an effective post-processing strategy for MDLP-fabricated 316L stainless steel and examines the microstructural origins of the observed property evolution.