State-of-the-Art Review on Fatigue Resistance of Lightweight Alloys Through Advanced Manufacturing Techniques

The pursuit of enhanced lightweight materials is intensifying, with stakeholders in metallurgy, thermal/mechanical treatments, and materials fabrication converging to develop high-performance alloys. Aluminum (Al), Titanium (Ti), and Magnesium (Mg) based alloys are at the forefront, drawing significant attention. Among their critical properties, fatigue performance—alongside corrosion resistance is crucial. This review aims to unify perspectives from diverse domains on factors affecting fatigue behavior, fostering collaborative progress in material and process development. The literature on Al, Ti, and Mg-based alloys was systematically reviewed, categorized, and presented for easy access. The influence of alloying elements, phases, and microstructures on fatigue properties is examined. Additionally, the impacts of thermal and thermo-mechanical treatments—including roller burnishing, peening, deep rolling, severe plastic deformation, hydrostatic extrusion, and friction stir processing on microstructural evolution and fatigue enhancement are highlighted.