{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,9,2]],"date-time":"2026-09-02T15:15:26Z","timestamp":1788362126473,"version":"build-2803163510"},"reference-count":75,"publisher":"MDPI AG","issue":"17","license":[{"start":{"date-parts":[[2026,9,2]],"date-time":"2026-09-02T00:00:00Z","timestamp":1788307200000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"name":"Chongqing Technology Innovation and Application Development Special Key Project","award":["CSTB2023TIAD-KPX0019"],"award-info":[{"award-number":["CSTB2023TIAD-KPX0019"]}]},{"name":"Natural Science Foundation of Chongqing, China","award":["CSTB2025NSCQ-WZQLHJJZDX0006"],"award-info":[{"award-number":["CSTB2025NSCQ-WZQLHJJZDX0006"]}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Materials"],"abstract":"<jats:p>Ti\u20136Al\u20134V alloy is widely used in aerospace and other high-performance engineering components, but its service reliability is often constrained by surface-initiated fatigue, fretting damage, wear, and corrosion. Ultrasonic surface rolling process (USRP) couples a static rolling force with high-frequency mechanical impacts to introduce severe plastic deformation while retaining relatively low surface roughness, thereby producing a gradient-strengthened surface layer. This review systematically summarizes advances in USRP strengthening of Ti\u20136Al\u20134V alloy within a \u201cprocess\u2013microstructure\u2013surface integrity\u2013service performance\u201d framework. The effects of static load, ultrasonic amplitude and frequency, feed rate, spindle speed, processing passes, treatment temperature, and lubrication conditions are first compared. Particular attention is then paid to the mechanisms governing dislocation multiplication and rearrangement, grain subdivision, gradient nanostructure formation, the responses of the \u03b1 and \u03b2 phases, deformation-induced phase transformation, and the evolution of depth-dependent residual compressive stress. The intrinsic relationships between these mechanisms and surface roughness, hardness, strengthened layer depth, wear and corrosion resistance, fatigue performance, and fretting fatigue performance are subsequently clarified. Control strategies involving electropulsing, laser\/temperature assistance, deep cryogenic treatment, and coating combinations are further reviewed, together with methods for contact dynamics analysis, residual stress prediction, and data-driven optimization. The combined evidence indicates that the performance gains from USRP are jointly controlled by surface defects, gradient microstructure, and residual compressive stress; excessive load, processing passes, or heat input may weaken or even reverse the fatigue benefit because of defect accumulation, gradient mismatch, and residual stress relaxation. Current limitations include inconsistent reporting of process parameters, difficulty in quantitatively separating the contributions of different strengthening mechanisms, insufficient investigation of residual stress stability, and limited validation on complex components.<\/jats:p>","DOI":"10.3390\/ma19173738","type":"journal-article","created":{"date-parts":[[2026,9,2]],"date-time":"2026-09-02T14:35:29Z","timestamp":1788359729000},"page":"3738","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":0,"title":["Tailoring the Surface Integrity of Ti\u20136Al\u20134V Alloy by Ultrasonic Surface Rolling Process: A Review"],"prefix":"10.3390","volume":"19","author":[{"given":"Guo","family":"Li","sequence":"first","affiliation":[{"name":"International Joint Laboratory for Light Alloys (Ministry of Education), Chongqing University, Chongqing 400044, China"},{"name":"School of Industrial Engineering, Ningxia Vocational and Technical University, Yinchuan 750021, China"},{"name":"College of Materials Science and Engineering, Chongqing University, Chongqing 400044, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Xuefei","family":"Liu","sequence":"additional","affiliation":[{"name":"College of Materials Science and Engineering, Chongqing University, Chongqing 400044, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Siyuan","family":"Liu","sequence":"additional","affiliation":[{"name":"International Joint Laboratory for Light Alloys (Ministry of Education), Chongqing University, Chongqing 400044, China"},{"name":"College of Materials Science and Engineering, Chongqing University, Chongqing 400044, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Hao","family":"Chen","sequence":"additional","affiliation":[{"name":"Department of Materials Science and Engineering, University of Toronto, 184 College Street, Toronto, ON M5S 3E4, Canada"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Weidong","family":"Xie","sequence":"additional","affiliation":[{"name":"International Joint Laboratory for Light Alloys (Ministry of Education), Chongqing University, Chongqing 400044, China"},{"name":"College of Materials Science and Engineering, Chongqing University, Chongqing 400044, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Guobing","family":"Wei","sequence":"additional","affiliation":[{"name":"International Joint Laboratory for Light Alloys (Ministry of Education), Chongqing University, Chongqing 400044, China"},{"name":"College of Materials Science and Engineering, Chongqing University, Chongqing 400044, China"}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"1968","published-online":{"date-parts":[[2026,9,2]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"280","DOI":"10.1016\/j.measurement.2014.10.059","article-title":"Design-of-experiments application in machining titanium alloys for aerospace structural components","volume":"61","author":"Khanna","year":"2015","journal-title":"Measurement"},{"key":"ref_2","doi-asserted-by":"crossref","unstructured":"Xie, B., and Gao, K. 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