Shuo Wu

Carbon fiber-reinforced thermoplastic composites (CFRTPs) have attracted increasing attention in aerospace, transportation, marine engineering, and other advanced manufacturing fields owing to their high specific mechanical properties, impact resistance, weldability, reprocessibility, and potential recyclability. However, the high melt viscosity of thermoplastic matrices, the permeability limitations associated with different reinforcement architectures, and the chemical inertness of carbon fiber surfaces continue to restrict resin impregnation, interfacial bonding, defect control, and forming stability. This review systematically summarizes recent advances in CFRTP manufacturing from the perspective of material-derived processing challenges and interface engineering. First, representative thermoplastic matrix systems and reinforcement architectures are discussed, with emphasis on their effects on processability, crystallization behavior, resin flow, and load transfer. Subsequently, six major forming processes, including hot stamping, injection molding, pultrusion, filament winding, automated fiber placement, and additive manufacturing, are critically compared in terms of processing principles, typical defects, technical limitations, and application boundaries. Particular attention is given to process-induced quality issues such as voids, wrinkling, springback, fiber breakage, warpage, insufficient consolidation, and weak interlayer bonding. Finally, interface engineering strategies, including chemical surface modification, interfacial structural design, and functional interlayer design, are reviewed as practical routes to improve wetting, shorten impregnation pathways, and enhance fiber–matrix load transfer in high-viscosity thermoplastic systems. This review highlights that CFRTP manufacturing should be understood as a coupled materials–processing–interface problem rather than a single forming operation. Future development is discussed with emphasis on reproducible manufacturing, processability-oriented materials, scalable interface engineering, predictive modeling, and standardized structural validation.

Ni-W-Y₂O₃ composite coatings were electrodeposited from a sulfate citrate electrolyte incorporating Y₂O₃ particles of three different sizes: 50 nm, 1 μm, and 2 μm. This study systematically investigates the impact of Y₂O₃ particle size on the microstructure, microhardness, corrosion resistance, and wear resistance of the composite coatings. The incorporation of Y₂O₃ particles leads to notable grain refinement, with the crystallite size decreasing from 31.8 nm for the pure Ni W coating to 17.3 nm, 19.0 nm, and 20.1 nm for the C-50 nm, C-1 μm, and C-2 μm coatings, respectively. Correspondingly, the microhardness increases from 540.2 HV for the unreinforced coating to 732.5 HV, 641.0 HV, and 629.5 HV for the C-50 nm, C-1 μm, and C-2 μm coatings, respectively. In terms of corrosion resistance, the C-50 nm coating exhibits the best performance in both acidic and neutral media, with the lowest corrosion current density of 3.72 μA/cm² in 10 wt.% H₂SO₄ and 3.53 μA/cm² in 3.5 wt.% NaCl. In contrast, micron-sized particles show limited improvement in acidic media and even degrade the corrosion resistance in neutral NaCl solution, where the corrosion current density increases to 7.68 μA/cm² and 7.74 μA/cm² for the C-1 μm and C-2 μm coatings, respectively. The wear resistance of the composite coatings is significantly enhanced by the incorporation of Y₂O₃ particles, with the wear rate decreasing from 17.75 × 10⁻⁶ mm³ N⁻¹ m⁻¹ for the pure Ni-W coating to 5.65 × 10⁻⁶ mm³ N⁻¹ m⁻¹ for the C-50 nm coating. The presence of Y₂O₃ particles transitions the wear mechanism from predominantly adhesive wear to a combination of adhesive and abrasive wear. These results demonstrate that the particle size of Y₂O₃ plays a critical role in determining the microstructure and overall performance of Ni-W-Y₂O₃ composite coatings, with nano-sized particles offering the most significant improvements.

Graphene (GR) demonstrates significant potential in enhancing the mechanical performance of titanium matrix composites (TMCs), particularly by improving their tensile strength, fracture toughness, and fatigue resistance, thereby optimizing the overall structural integrity and durability of the composites; however, their practical implementation confronts two fundamental challenges: achieving uniform dispersion and mitigating excessive interfacial TiC formation, which compromises mechanical properties. This review comprehensively explores progress in the fabrication, interfacial design, and mechanical optimization of TMCs reinforced with graphene-based materials. Various processing techniques, such as powder metallurgy (PM) and spark plasma sintering (SPS), are critically analyzed in terms of their advantages and limitations for producing high-performance TMCs. This article analyzes how key parameters in processes like PM and SPS affect graphene structure, dispersion, and interfacial reactions. It outlines strategies—including surface modification, 3D structural design, and multiscale interface engineering—that enhance both strength and toughness. While progress has been made in microscale performance, challenges remain in engineering stability and long-term reliability. Future work should focus on intelligent process optimization and architectured composite manufacturing. By systematically synthesizing existing research findings, this article clarifies the advantages and limitations of current technological approaches, providing a theoretical foundation and technical roadmap for the subsequent development of graphene-reinforced TMCs that exhibit high strength, high toughness, and excellent reliability.

A novel Corrax (CX) stainless steel was fabricated using the Selective Laser Melting (SLM) process. This study examined the influence of heat treatment processes on the microstructure and mechanical properties of CX stainless steel. Results indicate that SLM-fabricated CX samples mainly consist of martensite and residual austenite, with tensile strength and hardness of 1124 MPa and 337.4 HV, respectively. After solution treatment at 850 °C for 0.5 h (ST), the sample exhibited the highest martensite content, with nearly all residual austenite eliminated. Nickel and aluminum are fully dissolved within the matrix, leading to a supersaturated solid solution. This martensitic structure with a high dislocation density lays an important foundation for the subsequent aging treatment. Subsequent aging treatments at various temperatures demonstrate that when CX samples are subjected to solution aging at 850 °C for 0.5 h followed by aging at 525 °C for 4 h (ST + AT), all residual austenite is fully converted to martensite. The elements dissolved during the solution treatment precipitate, forming NiAl intermetallic compounds. This process leads to a substantial increase in tensile strength and surface hardness, achieving values of 1743 MPa and 526.8 HV, respectively. These results indicate that the solution and aging heat treatment significantly enhances the overall performance of CX samples.

The extended immersion of ships in seawater frequently results in biofouling, a condition characterized by the accumulation of marine organisms such as barnacles and algae. To combat this issue, the application of anti-fouling coatings to the hull surfaces of vessels has emerged as one of the most effective strategies. In response to the increasing global emphasis on environmental sustainability, there is a growing demand for anti-fouling coatings that not only demonstrate superior anti-fouling efficacy but also adhere to stringent environmental standards. The traditional use of organotin-based self-polishing anti-fouling coatings, known for their high toxicity, has been prohibited due to environmental concerns. Consequently, there is a progressive shift toward the development and application of environmentally friendly anti-fouling coatings. This paper reviews the toxicity and application limitations associated with conventional anti-fouling coatings. It provides a comprehensive overview of recent advancements in the field, including the development of novel self-polishing anti-fouling coatings, low surface energy coatings, biomimetic coatings, and nanostructured coatings, each leveraging distinct anti-fouling mechanisms. The paper evaluates the composition and performance of these emerging coatings and identifies key technical challenges that remain unresolved. It also proposes a multi-faceted approach to addressing these challenges, suggesting potential solutions for enhancing the effectiveness and environmental compatibility of anti-fouling technologies. The paper forecasts future research directions and development trajectories for marine anti-fouling coatings, emphasizing the need for continued innovation to achieve both environmental sustainability and superior anti-fouling performance.

Graphene nanoplates (GNPs)/TA15 composites were fabricated by pre-sintering and hot extrusion. During a room temperature tensile test, the dislocation was generated in grains. With increasing strain, the dislocation piled up along the interface between GNPs and Ti matrix, leading to stress concentration and microcracks. Then, the microcracks extended to GNPs or along the interface. The GNPs cracked under the shear force and the GNPs pulled out along with the crack propagation along the interface. This work provides a new sight in the room temperature tensile fracture behaviors.