Magnesium alloys are widely employed in various applications due to their high strength-to-weight ratio and superior mechanical properties as compared to unalloyed Magnesium. Alloying is considered an important way to enhance the strength of the metal matrix composite but it significantly influences the damping property of pure magnesium, while controlling the rate of corrosion for Mg-based material remains critical in the biological environment. Therefore, it is essential to reinforce the magnesium alloy with a suitable alloying element that improves the mechanical characteristics and resistance to corrosion of Mg-based material. Biocompatibility, biodegradability, lower stress shielding effect, bio-activeness, and non-toxicity are the important parameters for biomedical applications other than mechanical and corrosion properties. The development of various surface modifications is also considered a suitable approach to control the degradation rate of Mg-based materials, making lightweight Mg-based materials highly suitable for biomedical implants. This review article discusses the various binary and ternary Mg alloys, which are mostly composed of Al, Ca, Zn, Mn, and rare earth (RE) elements as well as various non-toxic elements which are Si, Bi, Ag, Ca, Zr, Zn, Mn, Sr, Li, Sn, etc. The effects of these alloying elements on the microstructure, the mechanical characteristics, and the corrosion properties of Mg-based materials were analyzed. The mechanical and corrosion behavior of Mg-based materials depends upon the percentage of elements and the number of alloying elements used in Mg. The outcomes suggested that ZEK100, WE43, and EW62 (Mg-6% Nd-2% Y-0.5% Zr) alloys are effectively used for biomedical applications, having preferable biodegradable, biocompatible, bioactive implant materials with a lower corrosion rate.

Manufacturing sectors, including automotive, aerospace, military, and aviation, are paying close attention to the increasing need for composite materials with better characteristics. Composite materials are significantly used in industry owing to their high-quality, low-cost materials with outstanding characteristics and low weight. Hence, aluminum-based materials are preferred over other traditional materials owing to their low cost, great wear resistance, and excellent strength-to-weight ratio. However, the mechanical characteristics and wear behavior of the Al-based materials can be further improved by using suitable reinforcing agents. The various reinforcing agents, including whiskers, particulates, continuous fibers, and discontinuous fibers, are widely used owing to enhanced tribological and mechanical behavior comparable to bare Al alloy. Further, the advancement in the overall characteristics of the composite material can be obtained by optimizing the process parameters of the processing approach and the amount and types of reinforcement. Amongst the various available techniques, stir casting is the most suitable technique for the manufacturing of composite material. The amount of reinforcement controls the porosity (%) of the composite, while the types of reinforcement identify the compatibility with Al alloy through improvement in the overall characteristics of the composites. Fly ash, SiC, TiC, Al₂O₃, TiO₂, B₄C, etc. are the most commonly used reinforcing agents in AMMCs (aluminum metal matrix composites). The current research emphasizes how different forms of reinforcement affect AMMCs and evaluates reinforcement influence on the mechanical and tribo characteristics of composite material.

Magnesium (Mg) has attracted considerable attention as a biodegradable material for medical implants owing to its excellent biocompatibility, mitigating long-term toxicity and stress shielding. Nevertheless, challenges arise from its rapid degradation and low corrosion resistance under physiological conditions. To overcome these challenges, titanium (biocompatibility and corrosion resistance) has been integrated into Mg. The incorporation of titanium significantly improves mechanical and corrosion resistance properties, thereby enhancing performance in biological settings. Mg–Ti alloys are produced through mechanical alloying and spark plasma sintering (SPS). The SPS technique transforms powder mixtures into bulk materials while preserving structural integrity, resulting in enhanced corrosion resistance, particularly Mg80-Ti20 alloy in simulated body fluids. Moreover, Mg–Ti alloy revealed no more toxicity when assessed on pre-osteoblastic cells. Furthermore, the ability of Mg–Ti-based alloy to create composites with polymers such as PLGA (polylactic-co-glycolic acid) widen their biomedical applications by regulating degradation and ensuring pH stability. These alloys promote temporary orthopaedic implants, offering initial load-bearing capacity during the healing process of fractures without requiring a second surgery for removal. To address scalability constraints, further research is necessary to investigate additional consolidation methods beyond SPS. It is essential to evaluate the relationship between corrosion and mechanical loading to confirm their adequacy in physiological environments. This review article highlights the importance of mechanical characterization and corrosion evaluation of Mg–Ti alloys, reinforcing their applicability in fracture fixation and various biomedical implants.

Polymer composites reinforced with nanofillers, synthetic fibers, and inorganic fillers have progressed rapidly, yet recent advances remain fragmented across filler-specific studies and often lack unified mechanistic interpretation. This review addresses this gap by presenting an interphase-centric, mechanism-driven framework linking processing routes, dispersion and functionalization requirements, interphase formation, and the resulting structure–property relationships. Representative quantitative datasets and mechanistic schematics are integrated to rationalize nonlinear mechanical reinforcement, percolation-controlled electrical/thermal transport, and thermal stabilization and barrier effects across major filler families. The review highlights how reinforcement efficiency is governed primarily by interfacial adhesion, filler connectivity, and processing-induced microstructural evolution rather than filler loading alone. Key challenges limiting scalability are critically discussed, including dispersion reproducibility, viscosity and processability constraints, interphase durability, and recycling compatibility. Finally, mechanism-based design rules and future outlook directions are provided to guide the development of high-performance, multifunctional, and sustainability-oriented polymer composite systems.

Complex structures can now be manufactured easily utilizing AM technologies to meet the pre-requisite objectives such as reduced part numbers, greater functionality, and lightweight, among others. Polymers, metals, and ceramics are the few materials that can be used in AM technology, but metallic materials (Magnesium and Aluminum) are attracting more attention from the research and industrial point of view. Understanding the role processing parameters of laser-based additive manufacturing is critical to maximize the usage of material in forming the product geometry. LPBF (Laser powder-based fusion) method is regarded as a potent and effective additive manufacturing technique for creating intricate 3D forms/parts with high levels of precision and reproducibility together with acceptable metallurgical characteristics. While dealing with LBPF, some degree of porosity is acceptable because it is unavoidable; hot ripping and cracking must be avoided, though. The necessary manufacturing of pre-alloyed powder and ductility remains to be the primary concern while dealing with a laser-based additive manufacturing approach. The presence of the Al-Si eutectic phase in AlSi10Mg and AlSi12 alloy attributing to excellent castability and low shrinkage, attaining the most attention in the laser-based approach. Related studies with these alloys along with precipitation hardening and heat treatment processing were discussed. The Pure Mg, Mg-Al alloy, Mg-RE alloy, and Mg-Zn alloy along with the mechanical characteristics, electrochemical durability, and biocompatibility of Mg-based material have been elaborated in the work-study. The review article also summarizes the processing parameters of the additive manufacturing powder-based approach relating to different Mg-based alloys. For future aspects, the optimization of processing parameters, composition of the alloy, and quality of powder material used will significantly improve the ductility of additively manufactured Mg alloy by the LPBF approach. Other than that, the recycling of Mg-alloy powder hasn’t been investigated yet. Meanwhile, the post-processing approach, including a homogeneous coating on the porous scaffolds, will mark the suitability in terms of future advancements in Mg and Al-based alloys.

Carbon nanotube (CNT) and graphene-reinforced nanocomposites have become exceptional multifunctional materials because of their exceptional mechanical, thermal, and electrical properties. Recent developments in synthesis methods, dispersion strategies, and interfacial engineering have effectively overcome agglomeration-related limitations by significantly improving filler distribution, matrix compatibility, and load-transfer efficiency. These nanocomposites have better wear durability, corrosion resistance, and surface properties like super-hydrophobicity. A comparative analysis of polymer, metal, and ceramic matrices finds benefits for applications in biomedical, construction, energy, defense, and aeronautics. Functionally graded architecture, energy-harvesting nanogenerators, and additive manufacturing are some of the new fabrication processes that enhance design flexibility and functional integration. In recent years, scalability, life-cycle evaluation, and environmentally friendly processing have all gained increased attention. The development of next-generation, high-performance graphene and carbon nanotube (CNT)-based nanocomposites is critically reviewed in this work, along with significant obstacles and potential next steps.