Secondary Aluminum Alloys for Functional Powder Materials: Mechanochemical Processing, MOF-Based Interfacial Modification, and High-Temperature Applications

This review examines current approaches to the development of multicomponent functional systems based on secondary aluminum alloys, mechanochemically modified metal powders, metal–organic frameworks, and aerosol-generating materials. It is shown that controlling the morphology, particle size, phase composition, and surface state of aluminum-containing powders is among the key factors governing their reactivity in high-temperature processes. Particular attention is paid to mechanochemical activation as a method for the controlled modification of particle structure, enhancement of crystal lattice defect density, formation of new interfacial contacts, and surface modification. The potential of metal–organic frameworks for interfacial modification, structural functionalization, and incorporation of active sites is critically assessed, while emphasizing that direct experimental evidence for their integration with secondary-aluminum-based powder systems remains limited. The use of carbon-containing and mineral materials for the preparation of aerosol-generating systems with tailored optical and spectral characteristics is analyzed separately. The application of secondary aluminum alloys is shown to provide opportunities for reducing production costs, improving resource efficiency, and advancing import-substitution technologies. The review identifies the integration of secondary aluminum alloys, mechanochemical activation, SHS, and MOF-based functionalization as an emerging research direction and highlights the need for further experimental validation, quantitative comparison, and pilot-scale assessment before such systems can be regarded as an established technological platform.