A synergistic balance of strength and ductility was achieved in a prototypical fcc-based Al_0.3CoCrFeNi complex concentrated alloy by incorporating hierarchical microstructural features into heterogeneous grain structure. Microstructural hierarchy was composed of different morphologies and size-scales of B2 precipitates and nano-twins that were incorporated in parent fcc matrix, which, additionally, was comprised of domains of fine and coarse grains. Strain partitioning between refined and coarse grains produced geometrically necessary dislocations during plastic deformation. This facilitated long-range back stresses during further deformation leading to simultaneous enhancement of strength and ductility. Furthermore, B2 precipitates complemented back stress and increased inherent matrix strength. GRAPHICAL ABSTRACT IMPACT STATEMENT Architecting hierarchical microstructural features into a heterogeneous grain structured complex concentrated alloy avoided the classic strength-ductility trade-off paradigm.

Under tensile shear loading, fracture modes of dissimilar lap welds produced by friction stir scribe technology were studied. Three fracture modes were observed. For zone A fracture, the initial crack was restrained, and the joint ultimately fractured in the base mild steel. For zone B fracture, the initial crack progressed through the aluminium sheet just above the Al/steel interface. For zone C fracture, the initial crack proceeded along the steel hook to the aluminium sheet surface. Fracture mode and joint strength were greatly influenced by steel hook size, and the steel hook size was affected by welding parameters and tool scribe height. In this study, the experimental joint strength achieved the calculated joint load limit.

Although recycling secondary aluminum can lead to energy consumption reduction compared to primary aluminum manufacturing, products produced by traditional melt-based recycling processes are inherently limited in terms of alloy composition and microstructure, and thus final properties. To overcome the constraints associated with melting, we have developed a solid-phase recycling and simultaneous alloying method. This innovative process enables the alloying of 6063 aluminum scrap with copper, zinc, and magnesium to form a nanocluster-strengthened high-performance aluminum alloy with a composition and properties akin to 7075 aluminum alloy. The unique nanostructure with a high density of Guinier-Preston zones and uniformly precipitated nanoscale η‘/Mg(CuZn)₂ strengthening phases enhances both yield and ultimate tensile strength by >200%. By delivering high-performance products from scrap that are not just recycled but upcycled, this scalable manufacturing approach provides a model for metal reuse, with the option for on-demand upcycling of a variety of metallic materials from scrap sources.

Friction stir scribe technology, a derivative of friction stir welding, was applied for the dissimilar lap welding of an aluminium alloy and galvanised mild steel sheets. During the process, the rotating tool with a cobalt steel scribe first penetrated the top material – aluminium – and then the scribe cuts the bottom material – steel. The steel was displaced into the upper material to produce a characteristic hook feature. Lap welds were shear tested, and their fracture paths were studied. Welding parameters affected the welding features, including hook height, which turned out to be highly related to fracture position. Therefore, in this paper, the relationships among welding parameters, hook height, joint strength and fracture position are presented. In addition, the influence of zinc coating on joint strength was also studied.