Various techniques to control microstructures and performances have been developed to address the problems of microstructure defects, residual stress, and anisotropy in metal additive manufacturing components. Based on the recent work performed in associated with additive manufacturing assisted by ultrasonic energy field, this paper analyzes the “liquid–solid” dual effect of ultrasonic impact, and summarizes the influence of ultrasonic impact treatment on the microstructure, surface roughness, microhardness, residual stress, corrosion resistance and other properties of additive metal materials. The results show that ultrasonic energy field ensures that the internal microstructure and grain size are significantly refined, the porosity is reduced, and the corrosion resistance is improved. At the same time, the microhardness of the additive component increases, and the residual tensile stress is transformed into residual compressive stress that is beneficial to the mechanical properties of the parts.

As an effective means of performance enhancement for aviation components, high-energy beam surface modification is applicable for all kinds of metals and alloys, which can significantly increase the surface hardness, wear resistance, corrosion resistance and et al. This paper summarizes the basic principles, equipment structures and modification applications of six different high-energy beam surface modification techniques. Laser transformation hardening can strengthen the steel surface via martensitic phase change; laser cladding achieves surface repair and surface performance improvement by choosing diverse powders, which focuses on how to control the crack defects; laser shock peening can efficiently solve the problem of high-cycle fatigue fracture of aircraft engine components; high current pulsed electron beam and high current pulsed ion beam should improve equipment performance and operation stability on one hand, and positively carry out modification attempts for aviation component on the other hand; and ion beam assisted deposition can effectively repair fretting wear by preparing solid lubrication coatings. Finally, the development of further research on surface modification mechanism of high-energy beam, development of specialized intelligent equipment, realization of multi-beam source composite and integration are proposed

Typically, ceramics are sintered at temperatures of above 1000 ℃ by traditional sintering route, resulting in long sintering time and high energy consumptions. The high sintering temperatures adversely affect the interface control, phase stability, and material co-sintering, and thus, it is challenging to co-sinter ceramics and polymers with polymers as the fillers. Cold sintering process, employing an intermediate liquid phase and dissolution–precipitation process, enables rapid densification of ceramics at temperatures ≤300 ℃ , which effectively addresses the co-sintering issue of ceramics and polymers. This review introduces the development of cold sintering process, sintering parameters and cold sintering mechanisms. The application and current status of cold sintering process in ceramic–polymer composites, such as microwave dielectrics, ferroelectrics, lithium-ion batteries, varistors, semiconductors and thermoelectric materials, are discussed in detail. Finally, the challenges and future prospects of cold sintering process are analyzed.

An Al plating layer was deposited on the surface of CoCrNiAlY–YSZ–LaMA dual ceramic coating by arc ion plating (AIP). The high temperature oxidation behaviors of these coatings during the air exposure were comprehensively characterized by using XRD, SEM and EDS. Results showed that LaMA coating without Al plating layer underwent severe volume shrinkage during the oxidation test, which triggered the initiation and propagation of longitudinal micro-cracks. These micro-cracks acted as the internal diffusion channels for O₂, triggering a sustained mass increase tendency, rapid TGO growth and severe elemental diffusion, and consequently resulted in a serious coating fracture. However, the coating with Al plating layer showed better high-temperature oxidation resistance and structural stability. The surface Al layer reacted with O₂ to generate an in situ dense Al₂O₃ barrier layer during the oxidation process, which prevented or delayed the internal penetration of O₂, and thus resulted in a very slow growth rate of TGO layer. The weight gain of this sample increased slightly from 8.59 mg/cm² at 20 h to 9.46 mg/cm² at 80 h. These current experimental results provided a new technical way and theoretical vision for the life-extension design of dual-ceramic thermal barrier coatings and the regulation of interfacial thermal growth stress.

Mo₂NiB₂ based cermet coating was prepared on the surface of Q235 low carbon steel by atmospheric plasma spraying, and laser remelting was carried out at 300 W and 500 W power. The results show that the laser remelting method can significantly reduce the defects of the coating, make the microstructure more dense, and the weak mechanical bonding at the interface is transformed into a good metallurgical bonding. With the increase of laser power, the bonding strength and corrosion resistance of the coating are improved, the maximum bonding strength is 38.08 MPa, and the minimum corrosion current is 0.033 μA/cm²; But the hardness and wear resistance are reduced, the minimum hardness is 1781HV_0.2, and the maximum volume friction rate is 6.25×10^–5 mm³/(N·m). The hardness, bonding strength, wear resistance and corrosion resistance of the above plasma sprayed and two kinds of laser remelted Mo₂NiB₂ based cermet coatings were significantly higher than those of Q235 low carbon steel substrate.

Over the last two decades, ceramic binder jetting additive manufacturing (BJAM) has emerged as a revolutionary technique for fabricating complex ceramic components, demonstrating significant potential and value in critical domains such as aerospace, biomedicine, and electronic information. This article comprehensively reviews the fundamental principles, material selection, process methodologies, performance characteristics, and manufacturing defects of this technology, along with an in-depth outlook on future challenges and objectives. Initially, the article elucidates the forming principles of this technology, juxtaposing its advantages and limitations against other additive manufacturing processes. It then synthesizes global research advancements, focusing on ceramic powder treatment and its properties, binder configuration and its dynamical behavior in powder beds, process parameter adjustments, and subsequent densification post-processing, discussing how these factors impact the density, porosity, microstructure, and performance of both green bodies and final components. Lastly, based on existing research outcomes and application limitations, the paper proposes forward-looking recommendations for the development of powder materials, binder design, and process parameter optimization. This review aims to provide comprehensive guidance for understanding and applying ceramic binder jetting additive manufacturing in scientific research and engineering practices.

In recent years, with the rapid development of aviation and marine industry, engine blades with the advantages of high temperature resistance, long life and corrosion resistance have become important parts of the development of a new generation of aero engines and turbine engines. Thermal barrier coating (TBCs) is a commonly used thermal protection technology to provide thermal insulation for the metal substrate of the engine blade part, protecting it from hot gases and corrosive media. But on the other hand, the higher operating temperature of the engine makes the blades and their surface TBCs suffer from serious environmental sediment corrosion, resulting in premature failure, and the corrosion types mainly include thermal corrosion, CMAS corrosion, molten salt corrosion, etc. Corrosion has become a problem that limits the operating temperature and service life of TBCs, and anti-corrosion protection is the focus of research in the field of TBCs. In this paper, the main characteristics of TBCs dominated by Yttria-stabilized zirconia (YSZ) are briefly described, and then the reaction mechanism of different corrosion of TBCs is briefly described, focusing on the influence relationship between coating microstructure design, gradient coating design, coating component modification and doping modification and coating corrosion, and the characteristics between TBCs modification method and coating corrosion are expounded. Several methods for future coating improvement and protection are proposed, and finally the application of TBCs in ultra-high temperature environment and the development direction of corrosion protection are prospected.

The blisk consists of a number of blades arranged in a circular array on the hub. Because the blade is a weakly rigid part, tool wear, chatter and tool deformation are serious during finishing, which affect the further improvement of machining quality. A new combine machining technology of milling and grinding for full surface finishing was proposed. The blade is processed by grinding, while the blade root and flow path are processed by milling. The full surface machining was realized by controlling the joint error in the overlap area of grinding and milling tool rails. The experimental results show that the combined machining technology shows good machining quality, the tool connecting error is controlled within 0.01 mm, and the overall blade profile error is less than 0.04 mm. The feasibility of the multi-spindle array machining of the blisk is verified by the double spindle machining experiment, which can greatly improve the machining efficiency while ensuring the machining quality.

When the titanium alloy compressor blade of the aircraft engine works, due to the long period of highstrength service and foreign body damage, the blade will deform, dent, wear, crack and even break. Laser cladding technology has become one of the important methods of blade repair due to its small heat affected zone, good deposition performance, high forming accuracy and high degree of automation. The geometric characteristics of the melt pool are the key factors affecting the quality of the cladding, so this paper proposes an identification measurement algorithm based on image processing for the real-time monitoring of the melt pool. First of all, the ROI region is extracted by the image mask, and then the gamma transform is performed on ROI region, the threshold bination is valued to realize the segmentation of the melt pool area, the contour area feature is calculated for denoising, and finally the AABB enveloping box is used to extract the geometric characteristics of the molten pool, which realizes the real-time monitoring of the length and width of the molten pool during the cladding process. Finally, through the multi-parameter orthogonal experiment, the average recognition error of the verification algorithm is 0.24 mm.

CFRP (carbon fiber reinforced plastic) is widely used in aerospace field because of its excellent mechanical properties. Under the premise of ensuring the stiffness and strength of the aircraft, the application of CFRP can effectively improve the flight performance and reduce the weight of the aircraft, so as to achieve the purpose of energy saving and emission reduction, and improve the economic benefits of the aviation industry. CFRP is a typical difficultto-machining material, and in order to ensure that the structure has load-bearing capacity in different directions, CFRP multidirectional lamination is generally used in the aero-engine industry, which makes the anisotropy and inhomogeneity of the material more complex. In this paper, the milling fracture mechanism of CFRP unidirectional laminates and two kinds of CFRP multidirectional laminates is analyzed, and it is found that different fiber direction angles have great influence on the fracture mechanism during CFRP milling, resulting in different surface quality. Among them, bending fracture will lead to a sharp decline in surface quality, which should be avoided as far as possible, and the surface quality of bending fracture at different angles is also different. Based on this, an optimization method of tool cut-in angle in multidirectional CFRP milling is proposed, and the rationality of this method is verified by experiments. This method can effectively improve the machining quality of the first-stage composite fan blade of a certain engine.