The advancement of high-end equipment in aviation, aerospace, and marine engineering toward high precision and superior performance has driven an increasingly urgent demand for critical metal components. Development requirements for large-size dimension, high precision and enhanced reliability of such equipment impose stringent requirements on the manufacturing technologies for high performance metal components. Conventional thermo-mechanical forming processes are restricted by inherent bottlenecks, including high forming loads, difficulty in microstructure regulation and low forming limits, which render them inadequate to satisfy the manufacturing requirements of advanced metal components. Energy field-assisted forming technology introduces single or coupled energy fields including lasers, electric currents, electromagnetic fields, and ultrasonic fields. It exploits the synergistic thermal and athermal effects generated by energy field-material interactions to precisely control material deformation behavior, serving as a vital approach to breaking through the capability limitations of conventional thermo-mechanical manufacturing. This paper systematically reviews the state-of-the-art applications of single-energy field and multi-energy field composite forming technologies in metal plastic forming, analyzes the key bottlenecks in current technologies for engineering application, and prospects the future development trends of energy field-assisted manufacturing technology. This paper aims to provide a theoretical basis and technical references for the development and production of core components for high-end equipment.

针对（TiB+La₂O₃）/IMI834颗粒增强钛基复合材料开展了900~980 ℃、0.0003~0.03 s^-1条件下的超塑拉伸试验，研究了该复合材料的超塑性变形行为及微观组织演变规律。结果表明，随着变形温度升高，材料流动应力降低，断后伸长率呈先增后降的趋势；降低应变速率，流动应力减小，伸长率表现为先增大后减小的特征，且变形温度越低，峰值应力对应变速率的波动越敏感；在940 ℃、0.003 s^-1条件下，复合材料获得最大伸长率为564%；应变速率敏感性指数m均大于0.3，900~960 ℃时应力指数n介于2~3之间，980 ℃时n＞3，超塑变形激活能Q的平均值约为383 kJ/mol，表明900~960 ℃时复合材料超塑变形以晶界滑动和位错滑移协调为主，而在980 ℃时转变为位错滑移主导，超塑性能下降；钛基复合材料在变形初期晶粒细小，硅化物均匀分布，仅在TiB增强体两端因变形不协调产生孔洞；随着变形量增加，动态再结晶晶粒不断长大，基体内部逐步萌生孔洞，变形后期孔洞持续聚集连通，最终引发材料断裂失效。Superplastic tensile tests were conducted on (TiB+La₂O₃)/IMI834 particulate-reinforced titanium matrix composites at temperatures of 900–980 ℃ and strain rates of 0.0003–0.03 s^‒1. The superplastic deformation behavior and microstructural evolution of the composite were investigated. The results indicate that increasing deformation temperature reduces the flow stress, while the elongation to failure rises first and then declines. Reducing the strain rate leads to decreased flow stress, whereas the elongation first increases and subsequently decreases. The peak stress is more sensitive to variations in strain rate at lower deformation temperatures. A maximum elongation of 564% is achieved for the composite at 940 ℃ and 0.003 s^‒1. The strain rate sensitivity index m is higher than 0.3. The stress exponent n ranges from 2 to 3 within 900–960 ℃, and exceeds 3 at 980 ℃. The average activation energy Q for superplastic deformation is approximately 383 kJ/mol. These results reveal that the superplastic deformation is dominated by coordinated grain boundary sliding and dislocation slip at 900–960 ℃, whereas dislocation slip becomes the dominant mechanism at 980 ℃, resulting in degraded superplasticity. At the early deformation stage, the titanium matrix composite possesses fine grains with uniformly distributed silicides, and cavities only initiate at both ends of TiB reinforcements due to deformation incompatibility. As deformation proceeds, dynamically recrystallized grains continuously grow, and cavities gradually nucleate within the matrix. In the late deformation stage, cavities continuously aggregate and coalesce, eventually causing fracture failure of the material.

A Ti–48Al–2Cr–2Nb alloy was fabricated from Ti–4Cr–4Nb foils and high-purity Al foils via reaction synthesis. The alloy was heat-treated at high temperature and then cooled at different rates to reveal the influence mechanism of cooling rates on the microstructure of reaction-synthesized Ti–Al–Cr–Nb alloys. The results show that Ti–48Al–2Cr–2Nb alloy can be successfully prepared via reaction synthesis using Ti–4Cr–4Nb foils and high-purity Al foils. Adding β-stabilizing elements Cr and Nb to Ti foils allows the β phase to be retained as ordered B₂ phase at room temperature. Besides equiaxed γ-TiAl grains and γ-TiAl/α₂-Ti₃Al lamellar colonies, the alloy microstructure contains a B₂+γ structure with B₂ phase as the matrix. Heat treatment at 1300 ℃ can tune the volume fractions of various microstructures and effectively decrease the B₂ phase fraction of the alloy. Compared with equiaxed γ-TiAl zones, cooling rates have a much stronger effect on the microstructures of γ-TiAl/α₂-Ti₃Al lamellar colonies and B₂+γ composite zones in reaction-synthesized Ti–48Al–2Cr–2Nb alloy. During cooling of the reaction-synthesized Ti–48Al–2Cr–2Nb alloy, three phase transformations take place in sequence: β→γ, β→B₂, α→α+γ. With increasing cooling rates, the precipitation reactions β→γ and α→α+γ are suppressed to different extents, while the β→B₂ ordering transformation shows weak sensitivity to cooling rates.

Investigating the microstructural characteristics of titanium and titanium alloys during warm laser shock incremental forming is of great significance for understanding the high-strain-rate deformation response of materials and realizing the coordinated control of shape and performance. Laser shock incremental forming experiments from room temperature to 200 ℃ were carried out on commercial pure titanium TA1 foils. Electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM) were utilized to characterize the microstructures of microchannel components fabricated at different forming temperatures. The results reveal that the microscopic plastic deformation mechanism during warm laser shock incremental forming is dominated by the synergistic effect of dislocation slip and deformation twinning, which is remarkably affected by forming temperature. As the temperature rises, the twin fraction of formed specimens declines, while the basal texture is continuously strengthened. Meanwhile, the fraction of low-angle grain boundaries first increases and then tends to be stable. At 150 ℃, the fraction of low-angle grain boundaries rises by 222.8%, and the kernel average misorientation value increases by 170.0%. This phenomenon arises from the combined effects of the high-strain-rate effect induced by laser shock and the thermal softening effect in warm forming.

The mechanisms through which rolling reduction ratio modulates the interfacial bonding strength and strength–ductility synergy of Ti/Al/Mg clad plates were systematically investigated. Ti/Al/Mg clad plates with various rolling reduction ratios were fabricated via hot rolling at 420 ℃. Combined with interfacial microstructure observation, elemental distribution characterization, grain structure analysis, as well as room-temperature shear and tensile mechanical tests, the influences of rolling reduction ratio on interfacial bonding behavior, microstructural evolution and mechanical response were clarified. The results reveal that excessively low reduction ratio causes weak metallurgical interfacial bonding, while overly high reduction ratio triggers shear localization within the Mg layer and consequently brittle fracture. The rolling reduction ratio of 65% is determined as the optimal process parameter; under this condition, the clad plate exhibits a shear strength of 72 MPa, ultimate tensile strength of 332 MPa and elongation of 14.2%, realizing the optimal matching of interfacial bonding performance and strength–ductility. The elevation of interfacial bonding strength originates from the evolution of interlocking mechanical meshing structure at Al/Mg interface, thickened elemental diffusion layer and shifted tensile-shear failure path. The improvement in comprehensive mechanical properties stems from the synergistic contributions of grain refinement on both sides of the Al/Mg interface, residual local stored energy inside Mg layer and enhanced interfacial load transfer capacity. This work lays a theoretical foundation for the rolling process optimization of lightweight Ti/Al/Mg laminated composite plates.

AA2219 is widely used in the manufacture of monolithic structural components for aerospace equipment. To avoid the adverse effect of residual stress and springback on their service performances, a process route including hydroforming under W-temper and in-die stress relaxation aging treatment is proposed. Aiming at the in-die stress relaxation aging process, the stress relaxation aging behavior of W-temper AA2219 under various room temperature pre-strains and initial stress levels is investigated. Firstly, the complete stress relaxation aging experiments under various conditions for AA2219 were carried out, and room temperature tensile tests were conducted on fully stress relaxation aged specimens. The results show that the stress relaxation rate increases obviously with the growth of room temperature pre-strain or initial stress level. When the initial stress level is 120 MPa and room temperature pre-strain is 8%, the yield strength and ultimate tensile strength of the alloy after complete stress relaxation aging are 353 MPa and 458 MPa, respectively. Then, interrupted stress relaxation aging experiments under different conditions were carried out to obtain the evolution of yield strength of AA2219 during stress relaxation aging process. The results show that peak aging time is greatly advanced with the increase of room temperature pre-strain, while the initial stress level has an insignificant effect on the evolution of yield strength. Finally, EBSD and TEM microstructural characterization tests were performed on stress relaxation aged AA2219 specimens under various conditions and aging durations. The results show that precipitation strengthening serves as the primary strengthening mechanism of the alloy, and dislocation work hardening also enhances alloy strength. Their synergistic effect counteracts the adverse impact of grain coarsening on mechanical properties. This paper investigates the stress relaxation aging behavior of AA2219 under large room temperature pre-strain, which can provide theoretical guidance for the integrated process route of W-temper hydroforming and in-die stress relaxation aging treatment.

To investigate the effect of pulsed current on the mechanical behavior of TA16 titanium alloy during plastic deformation, electrically-assisted tensile tests under different current densities and room-temperature tensile comparative tests were conducted. The results demonstrate that the flow stress of TA16 titanium alloy decreases with the increase of current density but the decreasing amplitude gradually attenuates as the current density increases. When the current density increases from 0 A/mm² to 12.5 A/mm², the yield strength of TA16 titanium alloy decreases from 437 MPa to 266 MPa, and the tensile strength decreases from 608 MPa to 356 MPa, representing reductions of 39.1% and 41.4%, respectively. Microstructural observations indicate that pulsed current can effectively induce dislocation annihilation, reduce dislocation accumulation, result in a decrease in the proportion of low-angle grain boundaries and an increase in the proportion of high-angle grain boundaries, while enhancing the ratio of recrystallization. When the current density increases to 12.5 A/mm², the proportion of low-angle grain boundaries decreases from 75.6% at room-temperature tensile test to 63.9%, and the recrystallization ratio increases from 1.7% to 4.6%.

CNC machine tools are the core equipment in the field of precision machining such as aerospace manufacturing. The dynamic characteristics of its feed servo system directly determine the machining accuracy. Aiming at the problem that traditional parameter tuning relies on experience and is difficult to balance rapidity and stability, a collaborative optimization strategy combining staged hybrid identification and the adaptive genetic algorithm （AGA） is proposed. Firstly, the feed servo system model is established, and the frequency domain least squares method is used to provide high-precision initial states for the adaptive extended Kalman filter, so that the goodness of fit of parameter identification is increased to 0.99, which lays an accurate model foundation for controller optimization. Based on this model, the multi-objective optimization capability of AGA is used to perform global search on the normalized cost function to coordinate the contradiction between rapidity and stability. It is verified by experiments that this method can completely eliminate overshoot in uniaxial reciprocating motion and reduce the settling time by 5.5%. In multi-axis linkage contour machining, the maximum contour error, root mean square error and average contour error of the system can be reduced by 68.75%, 76.19% and 77.42% respectively, which has good engineering applicability.

Laser-electrochemical hybrid machining (LECM) based on tubular electrode is an emerging non-traditional machining method with great potential for high-efficiency and damage-free fabrication of high-aspect-ratio features in difficult-to-machine superalloys. The tubular electrode enables simultaneous coupling and transmission of laser, electrical, and fluid energy fields, thereby integrating the high efficiency of laser machining with the great surface integrity of electrochemical machining. In this paper, recent studies on LECM based on tubular electrodes are firstly reviewed, including electrode design and fabrication, hybrid field coupling mechanisms in material interaction, and representative results in high-aspect-ratio and high-quality small-hole machining. The structural principles and characteristics of various electrode configurations are analyzed, while the coupling and transmission mechanisms of both “flow-channel laser-guiding” and “optical fiber laser-guiding” tubular electrodes are systematically summarized. In addition, technical methods for achieving efficient laser-liquid energy-field coupling within tubular electrodes are further discussed. According to the dominant energy field in the hybrid machining process, the material removal mechanisms under the interactions of laser and electrochemical hybrid fields are discussed, distinguishing between laser-assisted electrochemical machining and electrochemical-assisted laser processing. Furthermore, the influence of the intensity and spatial distribution of the energy fields on material removal behavior is preliminarily investigated. Finally, representative experimental results on typical difficult-to-machine materials are presented. The potential applications and future development prospects of this technology are outlined. This paper aims to provide theoretical insights and technical guidance for further research and industrial implementation of LECM based on tubular electrodes.

Functional materials of carbonyl iron powder (CIP)/poly (ethylene terephthalate-co-1,4-cyclohexanedimethylene terephthalate) (PETG) were prepared by solution blending. The structure and properties of functional powders and filaments with different ratios were studied. The CIP/PETG functional powders and filaments were formed by selective laser sintering (SLS) and fused deposition modeling (FDM) respectively. The effects of different CIP mass fractions and forming processes on the properties of 3D printed products were investigated. The results show that: The fluidity of CIP/PETG functional powders is directly proportional to the CIP mass fraction. The angle of repose of the sample with 80% CIP mass fraction is 44.5°, and the Hausner ratio is 1.27, which basically meets the process requirements of SLS. For CIP/PETG functional filaments, the surface roughness decreases and the ultimate tensile strength increases with the decrease of CIP mass fraction. The 3D printed products of CIP/PETG functional materials possess heat conduction and electromagnetic absorption properties, and the thermoelectric effects are positively correlated with the CIP mass fraction. The thermal conductivities of the SLS-formed products and FDM-formed products with 80% CIP mass fraction are 0.88 W/(m・K) and 0.84 W/(m・K) respectively, and the average reflection loss in the frequency range of 8–18 GHz is –10.96 dB and –11.47 dB respectively.

The structural integrity of aircraft is a core element in ensuring the safety and service life of aircraft, and structural health monitoring (SHM) technology is a critical means to achieve this goal. Intelligent coating sensors, with the advantages of lightweight design, full-surface coverage and in-situ monitoring, possess great application potential in the field of structural health monitoring. Based on the damage concomitant effect, this study designed and fabricated two types of intelligent coating sensors with high-precision crack monitoring capacity, and their performance was validated through precision tests. The working mechanism of the sensors was verified via COMSOL electric current field simulations. For precision verification, fatigue loading tests were carried out on component-level specimens (a center single-hole panel and a large opening panel were taken as examples). The results demonstrated that for cracks with an average length of 0.57 mm in the center single-hole panel test, the measurement error of the sensor was 0.15 mm; In the large opening panel test, the measurement error reached 0.17 mm for cracks with an average length of 0.67 mm. The results fully verify the high-precision crack monitoring capacity of the sensors.

Helicopter rotor blades, being large parts with complex curved surfaces, significantly affect the performance of helicopters. Addressing the current challenges associated with blade profile detection, which primarily utilizes manual measurement tools characterized by low efficiency and unstable quality, a digital non-contact profile detection method for helicopter rotor blades based on combined measurements has been proposed. Initially, a measuring field is established and point cloud data are collected using industrial camera photogrammetry and laser scanners. To enhance the efficiency and automation level of the inspection process, a coordinate system transformation method based on the features of the blade root bore features has been developed. Experimental results demonstrate good consistency in blade profile detection indexes, with standard deviations of 0.354 mm for chord length, less than 0.15° for twist angle, and less than 0.026 mm for maximum airfoil thickness. These findings validate the effectiveness and accuracy of the proposed method.

Laser peening systems based on flexible light guide arms hold great potential for development due to their adaptability to complex structures. However, existing flexible light guide arms suffer from spot distortion, leading to reduced surface uniformity after laser peening. To clarify the impact of spot distortion on surface integrity, single-point impact and array scanning experiments were conducted in distinct regions. The results indicate that spot distortion originates primarily from assembly errors in the light guide arm lenses. The average spot diameter is approximately 1.48 mm, with inter-area variation less than 0.05 mm. The ellipticity of the light spot fluctuates between 1 and 1.1 across different regions. Within the same region, the standard deviation of single-point impact pit depth and half-height width are 0.15 μm and 0.08 mm, respectively. The p-value from the t-test comparing pit depths across different regions is significantly greater than 0.05. The arc height of the thin plate specimens is between 0.28 mm and 0.32 mm, indicating that the laser peening system based on the flexible light guide arm can ensure processing stability and consistency at the current level of spot distortion. These findings provide a solution for enhancing the consistency of laser peening processing in in-situ laser peening scenarios for complex components.