The durability and efficiency of electrochemical energy storage devices, including lithium-ion batteries and supercapacitors, are fundamentally constrained by mechanical and thermo-mechanical degradation. During electrochemical cycling, repeated volumetric expansion and contraction of solid-state electrodes generate internal stresses that can lead to particle fracture, electrode delamination, and loss of structural integrity. These damage mechanisms increase internal resistance, reduce capacity, and shorten device lifespan, while coupled thermal effects further accelerate degradation through a self-reinforcing feedback process. Conventional slurry-based electrode manufacturing offers limited control over the microstructural architecture, leading to electrodes that are prone to stress concentration and thermal instability. This review examines the role of advanced micro- and nano-manufacturing techniques, including electrospinning, freeze casting, atomic layer deposition, laser processing, and direct ink writing, in enabling mechanically robust and thermally resilient electrode architectures. From an engineering design perspective, these approaches allow the fabrication of compliant, hierarchical structures that accommodate strain, mitigate stress accumulation, and enhance heat dissipation. The review examines the interplay between fabrication methods, microstructure, mechanical behavior, and electrochemical performance, with a particular focus on fatigue, crack initiation, and growth. Finally, key research gaps are identified, including the lack of standardized mechanical testing, limited long-term fatigue data, and challenges in scalable manufacturing. The integration of multi-physics modeling and digital twin frameworks is proposed as a pathway toward more reliable next-generation energy storage systems.

Metal-organic framework (MOF)-derived carbon materials exhibit significant advantages in microwave absorption due to their excellent conductivity, structural diversity, and abundance of defects and interfaces. However, it is difficult to achieve a balance between magnetic loss and dielectric loss for most magnetic metal-based MOFs-derived absorbers. In this study, MIL-125(Ti) was prepared as a template, and then TiO2@C-x composites were obtained by a two-step pyrolysis method. The experimental findings showed that the pyrolysis temperature significantly influences the degree of graphitization and TiO2 crystal formation, which consequently affects the dielectric and microwave absorption properties for the investigated MIL-125(Ti)-derived core-shell TiO2@C composites. Among them, further research showed TiO2@C-700 presents a favorable and effective microwave absorption bandwidth of 3.2 GHz (9.2-12.4 GHz) at a thickness of 2.01 mm. Therefore, the MIL-125(Ti)-derived TiO2@C composites fabricated in this study provide great potential for the construction of tunable and efficient MOFs-derived microwave absorbers.

Conventional superhydrophobic coatings on aluminum alloys are frequently limited by inadequate coating–substrate adhesion, poor mechanical robustness, and the vulnerability of their surface micro/nanostructures to mechanical damage. To address these challenges, a hydroxyl-rich anodic oxide interlayer was formed via hard anodization followed by a hydroxylation treatment, thereby enhancing interfacial bonding and providing abundant active anchoring sites for coating deposition. Using this interface-engineering strategy, a mechanically durable superhydrophobic F-SiO₂@polyurethane (PU) composite coating with hierarchical micro/nanostructures was successfully fabricated on aluminum alloy substrates through a facile spray-coating process. The anodized substrate provides abundant hydroxyl groups and interfacial anchoring sites, while the PU matrix enhances structural integrity and facilitates particle fixation. Incorporating fluorinated SiO₂ nanoparticles produced a hierarchical micro/nanostructure with low surface energy. After 10,000 cm of abrasion and 200 tape-peeling cycles, the coating maintained contact angles above 150°. The coating maintained superior corrosion resistance during prolonged immersion in acidic, alkaline, and saline environments. The improved durability and corrosion resistance originate from the synergistic effects of strong interfacial bonding, polymer barrier protection, and the fluorinated hierarchical structure. This study offers a promising strategy for developing durable superhydrophobic coatings for long-term protection of aluminum alloys.

Conventional superhydrophobic coatings on aluminum alloys are frequently limited by inadequate coating-substrate adhesion, poor mechanical robustness, and the vulnerability of their surface micro/nanostructures to mechanical damage. To address these challenges, a hydroxyl-rich anodic oxide interlayer was formed via hard anodization followed by a subsequent hydroxylation treatment, thereby promoting interfacial bonding and providing abundant active anchoring sites for coating deposition. Based on this interface-engineering strategy, a mechanically durable superhydrophobic F-SiO₂@polyurethane (PU) composite coating with hierarchical micro/nanostructures was successfully fabricated on aluminum alloy substrates through a facile spray-coating process. The anodized substrate provides abundant hydroxyl groups and interface anchoring sites, while the PU matrix enhances structural integrity and facilitates particle fixation. By incorporating fluorinated SiO₂ nanoparticles, a hierarchical micro/nanostructure with low surface energy was fabricated. After 10,000 cm abrasion and 200 tape-peeling cycles, the coating maintained contact angles above 150°. The coating maintained superior corrosion resistance during prolonged immersion in acidic, alkaline, and saline environments. The improved durability and corrosion resistance originate from the synergistic effects of strong interfacial bonding, polymer barrier protection, and the fluorinated hierarchical structure. This study offers a promising strategy for developing durable superhydrophobic coatings for long-term protection of aluminum alloys.