Introduction

Aluminum, due to its abundance, low density, and good corrosion resistance, remains a material of significant interest across diverse fields. This mini-review examines recent advancements in aluminum-based materials over the past five years, focusing on two primary areas: aluminum-based battery technology and advancements in aluminum alloy manufacturing and processing, including sustainable approaches.

Aluminum-Based Battery Technology: Novel Materials and Electrolyte Optimization

The development of high-performance, cost-effective, and safe battery technologies is crucial for energy storage applications. Aluminum-ion batteries (AIBs) have emerged as a promising alternative to lithium-ion batteries due to the abundance and low cost of aluminum. Recent research has focused on developing novel cathode materials and optimizing electrolytes to improve the performance of AIBs.

Several research groups have explored various cathode materials. In 2020, Zhiqiang Niu's group demonstrated the use of engineered active sites on polyaniline for AlCl2+ storage (Shuai Wang et al., 2020, Angewandte Chemie International Edition). Jianling Li's group investigated SnSe nanoparticles as positive electrode materials (Yu Zhang et al., 2020, Chemical Engineering Journal) and later explored two-dimensional V2C@Se (MXene) composites (Wenrong Lv et al., 2021, Energy storage materials; Wenrong Lv et al., 2022, Energy storage materials). Hongsen Li and Guihua Yu's group designed two-dimensional WS2 layered cathodes (Zhongchen Zhao et al., 2020, Nano Today). Jiaqi Wan's group focused on interfacial engineering of Bi2Te3/Sb2Te3 heterojunctions (Yiqun Du et al., 2021, Energy storage materials). Kai Zhang's group explored high-energy-density quinone-based electrodes (Yixin Li et al., 2021, Advanced Functional Materials). More recently, Lili Wang's group investigated the effects of multiple ion reactions based on a CoSe2/MXene cathode (Zeyu Yuan et al., 2023, Advanced Materials), and Amreesh Chandra's group explored two-dimensional V2O5 nanosheets (Puja De et al., 2023, ACS Applied Energy Materials). Fengxia Geng's group worked on defect modulation in cobalt manganese oxide sheets (Jinlin Yang et al., 2023, Advanced Functional Materials). Lilong Xiong's group reviewed organic cathode materials (Huang Zhen et al., 2023, ChemSusChem).

Electrolyte optimization is another critical area of research. Chunshuang Yan, Qingyu Yan, and Guihua Yu's group demonstrated reversible Al metal anodes enabled by amorphization for aqueous aluminum batteries (Chunshuang Yan et al., 2021, Journal of the American Chemical Society; Chunshuang Yan et al., 2022, Journal of the American Chemical Society). Li Tan's group focused on ultra-fast charging by investigating electric double layers on the active anode (Xuejing Shen et al., 2021, Nature Communications). Wei-Li Song and Shuqiang Jiao's group developed stable high-capacity organic aluminum-porphyrin batteries (Xue Han et al., 2021, Advanced Energy Materials). Andinet Ejigu and Robert A. W. Dryfe's group worked on optimization of electrolytes for high-performance aqueous aluminum-ion batteries (Andinet Ejigu et al., 2022, ACS Applied Materials & Interfaces). Wei Wang and Shuqiang Jiao's group explored alternate storage of opposite charges in multisites for high-energy-density Al-MOF batteries (Yuxi Guo et al., 2022, Advanced Materials). Wenming Zhang and Zhanyu Li's group developed bimetallic rechargeable Al/Zn hybrid aqueous batteries (Xiaohu Yang et al., 2022, Advanced Materials). Xuebin Yu's group focused on solvation structure regulation for highly reversible aqueous Al metal batteries (Zhongchen Zhao et al., 2024, Journal of the American Chemical Society). Quanquan Pang's group developed rapid-charging aluminum-sulfur batteries operated at 85 °C with a quaternary molten salt electrolyte (Jiashen Meng et al., 2024, Nature Communications).

These studies highlight the ongoing efforts to develop advanced materials and electrolytes for AIBs, addressing challenges such as low energy density and poor cycle life.

Advancements in Aluminum Alloy Manufacturing and Processing

Significant progress has been made in aluminum alloy manufacturing and processing techniques, including additive manufacturing, welding, and surface treatment, to enhance mechanical properties, corrosion resistance, and overall performance.

In additive manufacturing, Gürel Çam's group discussed the prospects of producing aluminum parts by wire arc additive manufacturing (WAAM) (Gürel Çam et al., 2022, Materials Today Proceedings). Huaixue Li and Peng Liu's group reviewed laser additive manufacturing (LAM) of aluminum alloys (Hongju Fan et al., 2024, Optics & Laser Technology). Huijun Li's group worked on microstructure and mechanical properties of ultra-high strength aluminum alloy fabricated by wire-arc additive manufacturing (Xinpeng Guo et al., 2023, Journal of Material Science and Technology). Duck Bong Kim's group investigated stainless steel/aluminum bimetallic structures fabricated by cold metal transfer (CMT)-based wire-arc directed energy deposition (Md Abdul Karim et al., 2024, Additive manufacturing).

In welding, Zhi Zeng's group studied keyhole-induced porosity formation in laser beam oscillating welding (Wenchao Ke et al., 2020, Optics & Laser Technology). Gaoyang Mi's group studied laser beam oscillating welding characteristics for 5083 aluminum alloy (Shangren Li et al., 2020, Journal of Manufacturing Processes). Ming Gao's group focused on porosity suppression in oscillating laser-MIG hybrid welding of AA6082 aluminum alloy (Lei Wang et al., 2021, Journal of Materials Processing Technology). Chuansong Wu's group analyzed dynamic recrystallization in friction stir welding (Pengfei Yu et al., 2021, Acta Materialia). Mohd Ridha Muhamad's group reviewed friction stir butt welding of aluminum with magnesium (Usman Abdul Khaliq et al., 2023, Journal of Materials Research and Technology). Weifeng Xu's group studied the microstructure evolution and its effect on the corrosion of dissimilar aluminum alloys friction stir welding joint (Hongjian Lu et al., 2023, Corrosion Science). Xiangchen Meng, Yuming Xie, and Yongxian Huang's group worked on in-situ rolling friction stir welding of aluminum alloys towards corrosion resistance (Wei Wang et al., 2024, Corrosion Science). Shude Ji and Peng Gong's group studied the repair of mechanical holes in 2024 aluminum alloy by radial-additive friction stir repairing (Zhiqing Zhang et al., 2024, Journal of Materials Research and Technology). Chongjun Wu's group analyzed the quality and mechanical properties of 7075 aluminum alloy Friction Stir Welding (FSW) with WC-Co tool (Chongjun Wu et al., 2024, Materials Today Communications).

Surface treatment for corrosion protection has also seen advancements. Fabienne Peltier's group reviewed Cr-free coatings for the corrosion protection of aluminum aerospace alloys (Fabienne Peltier et al., 2022, Coatings (Basel)). Hao Wu's group improved the corrosion and wear resistance of micro-arc oxidation coatings on the 2024 aluminum alloy (Xi Ke et al., 2022, Applied Surface Science).

These advancements in manufacturing and processing contribute to the development of high-performance aluminum alloys for various applications.

Sustainable Aluminum Production and Recycling

The environmental impact of aluminum production is a growing concern, leading to increased research on sustainable manufacturing and recycling processes.

Stefan Pogatscher's group has consistently published on making sustainable aluminum by recycling scrap (Dierk Raabe et al., 2020, Progress in Materials Science; Dierk Raabe et al., 2021, Progress in Materials Science; Dierk Raabe et al., 2022, Progress in Materials Science). Shengen Zhang's group has focused on harmless disposal and resource utilization for secondary aluminum dross (Hanlin Shen et al., 2020, The Science of The Total Environment) and the microstructure evolution of recycled 7075 aluminum alloy (Bo Zhou et al., 2021, Journal of Alloys and Compounds; Rui Lin et al., 2022, Journal of Materials Research and Technology). Fengqin Liu and Hongliang Zhao's group developed a new approach to recover valuable elements in black aluminum dross (Zhengping Zuo et al., 2021, Resources Conservation and Recycling). Ting-an Zhang and Liping Niu's group analyzed the development scenarios and greenhouse gas (GHG) emissions in China’s aluminum industry (Shupeng Li et al., 2021, Journal of Cleaner Production). Zijian Su's group studied the self-driven hydrolysis mechanism of secondary aluminum dross (SAD) (Yuanbo Zhang et al., 2023, Chemical Engineering Journal). Xiu-Wen Wu and Shaopeng Li's group focused on the removal of nitrides and fluorides from secondary aluminum dross by catalytic hydrolysis (Zhanbing Li et al., 2023, Heliyon). Hu Liu's group provided a critical review of comprehensive treatments of aluminum dross in China (Chuan Wang et al., 2023, Journal of Environmental Management).

These studies highlight the importance of developing sustainable practices for aluminum production and recycling to minimize environmental impact.

Conclusion

The past five years have witnessed significant advancements in aluminum-based materials, particularly in battery technology and sustainable manufacturing. Research on aluminum-ion batteries has focused on developing novel cathode materials and optimizing electrolytes to improve energy density and cycle life. Simultaneously, advancements in aluminum alloy manufacturing and processing, including additive manufacturing, welding, and surface treatment, have enhanced the mechanical properties and corrosion resistance of aluminum alloys. Furthermore, increased attention has been given to sustainable aluminum production and recycling to minimize the environmental impact of the aluminum industry. These advancements collectively contribute to the continued relevance and expanding applications of aluminum-based materials in various sectors.

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