Methods for Preparing High-performance Al Alloy Materials

Abstract

Al alloys, with their low density, high plasticity, and excellent electrical/ thermal conductivity, have become the second most widely used metallic material after steel. They are extensively applied in aerospace, automotive, marine, and smart construction sectors. Common challenges in recent high-performance Al alloy production processes include “high-temperature coarsening of strengthening phases, multiscale interface instability, and microstructural inhomogeneity in large components”. This necessitates establishing a multiscale coupled model linking “process window-microstructural parameters-service limits”. This paper systematically reviews the latest patents across five major process directions over the past five years, analyzing the microstructural mechanisms and performance gains of key technologies such as “multiphase synergistic precipitation”, “dual-scale grain coupling”, “selfsealing ceramic films”, and “gradient nanocrystal stabilization”. It proposes an integrated design approach centered on “enhanced in-situ controllable phase formation - interfacial gradient adaptation - online defect suppression”, providing a roadmap for patent strategy and industrial implementation of next-generation Al alloys featuring high strength, toughness, corrosion resistance, and fatigue life.