Hai Hao

The rapid development of wireless communication technologies has intensified the demand for electromagnetic interference (EMI) shielding materials that simultaneously deliver high shielding effectiveness, robust mechanical performance, and low density. Here, guided by heterointerface engineering and structural reinforcement, fabricates bi‐continuous interpenetrating porous composite structures (BIPCs) by integrating ZL111 alloy lattice struts with an aluminum foam (AF). Three reinforcement architectures are designed: a cubic‐symmetric framework with unidirectional struts (Structure A), a lateral reinforcement (Structure B), and a longitudinal reinforcement (Structure C). Compared with AF, all BIPCs exhibit pronounced improvements in both compressive properties and EMI shielding. Among them, Structure C shows the largest mechanical enhancement, with compressive strength, specific strength, plateau stress, and elastic modulus increased to 2.06, 1.62, 1.42, and 2.25 times those of AF, respectively, while the total shielding effectiveness (SET) increases by 6.6%. The enhanced mechanical response is attributed to the cooperative load transfer provided by the alloy struts and metallurgical bonding in heterointerfaces. Meanwhile, EMI shielding was collaboratively enhanced by reflection loss improvement from the higher electrical conductivity and polarization losses evoked by lattice distortions. This work can not only provide idea for solving the problem of synergistic enhancement of mechanical and EMI shielding properties of AF, but also give a reference for subsequent research to enhance the EMI shielding properties of BIPCs.

High alloy content and multiphase synergistic strengthening have become crucial strategies in contemporary metallic materials design for performance enhancement. A major challenge in this field lies in addressing compositional segregation arising from differences in solute diffusion, especially in high‐alloy systems such as aluminum‐lithium (Al‐Li) alloys. This study explores the 2060 Al‐Li alloy, a representative high‐alloy system, produced using twin‐roll casting, a segregation‐sensitive process, and analyzes segregation behavior through a customized solute field model. The results reveal that nanoclusters with high solute tolerance effectively reduce segregation‐induced degradation, leading to significant improvements in both strength and ductility, with an 18.7% increase in strength and a 41.5% increase in elongation. Furthermore, a shear‐bypass synergistic strengthening mechanism was identified. This work not only unlocks the potential of the twin‐roll casting process by leveraging sub‐rapid solidification advantages but also offers a promising technical and theoretical approach to mitigating compositional segregation, addressing a long‐standing challenge within the high‐alloy metallic materials industry.