Microscale precision foil preparation and research on the microstructure of titanium foils

In recent years, with the rapid advancement of cutting-edge technologies such as aerospace, 3 C electronics, new materials, new energy, microscale precision foils have become increasingly vital, particularly titanium foils with typical hexagonal close-packed (HCP) structures have received significant attention. However, to date, a comprehensive and systematic overview of this topic remains lacking. This paper aims to fill this gap by providing a detailed overview of the preparation process and the macro-regulation and micro-mechanism studies concerning titanium foils. Specifically, the review focuses on recent progress in composition-process-organization relationships, deformation mechanism, and size effect coupling in titanium foils with typical HCP structures. First, the various preparation methods and underlying principles for different categories of microscale precision foils are summarized, with an emphasis on traditional rolling and precision rolling techniques in terms of their similarities and distinctions. Next, the effects of composition design and thermo-mechanical processing (rolling and heat treatment) on microstructure evolution, mechanical properties, deformation behavior, and size effect of microscale titanium foils are thoroughly analyzed. Finally, current challenges in the fabrication and fundamental understanding of microscale precision titanium foils are outlined, along with perspectives on future research directions in theoretical research and advanced processing technologies. • Examines foil process challenges and titanium foil research, guiding future studies. • Precision rolling delivers shape accuracy, surface finish, and key properties. • Analyzed titanium foil's plastic deformation mechanisms and size effects. • Comprehensive overview of titanium foil composition, processing, and properties. • For advanced materials, fusion-driven methods build theoretical models and systems.