Xuanyu Sheng, a fifth-year PhD student in the School of Materials Engineering.

Sectors like aerospace and automotive depend on innovative material compositions and tweaks to microstructure to deliver the high-performing features that drive their operating needs. High-strength aluminum alloys are especially critical to this equation, punching above their weight to deliver durability, performance, energy efficiency, and sustainability. Xuanyu Sheng is a fifth-year PhD student in the School of Materials Engineering who wants to push the envelope around microstructure to develop new alloys with enhanced properties that can provide industry with a freer, more flexible hand in designing higher performing products.

What is your research focus, what investigative avenues are you pursuing?

My thesis research focuses on designing high-strength aluminum (Al) alloys. Al alloys are among the most widely used materials due to their excellent strength-to-weight ratio and are critical to industries such as automotive and aerospace. My research explores new microstructural design strategies to push the limits of strength and ductility. I want to develop lightweight, high-performance Al alloys that can contribute to energy efficiency and sustainability across industries.

What spurred your interest in this particular topic and line of research?

My interest in materials science was initially sparked by the global push for clean energy technologies. I saw how critical it was to develop high-performance materials for applications like lithium-ion batteries, which led me to pursue materials science. During my undergraduate senior design project, I worked on 3D printing of Ni-based superalloys using laser powder bed fusion. That experience opened my eyes to the transformative potential of additive manufacturing — especially its growing role in aerospace and automotive sectors.

Why did you choose Purdue to continue your studies as a graduate student?

I’ve been at Purdue for nine years — four as an undergraduate and now five as a Ph.D. student. Staying for graduate school was an easy decision. I greatly enjoy working with my advisor, Professor Xinghang Zhang, who heads up the Zhang Nanometal Group. He offers his students both intellectual freedom and strong mentorship. Purdue also provides extensive resources for interdisciplinary collaboration, industry connections, and research funding. The environment here encourages exploration and innovation.

When did you first get interested in engineering and science?

Growing up in a developing country, I was deeply influenced by a common saying: “Science and technology are the primary productive forces.” I believed early on that becoming an engineer or scientist would give me the best opportunity to make a meaningful impact on society.

What’s it like studying at Purdue?

It’s a privilege to work alongside such capable peers and mentors. The environment is collaborative and intellectually stimulating. Whenever I encounter a challenge in my research, I can always find insightful suggestions or inspiration from others around me. I’ve also found that many of my colleagues are assertive and persistent — qualities that I admire, and that foster meaningful scientific progress.

Beyond subject matter, what else have you learned as a Purdue graduate student?

The most valuable lesson I’ve learned is how to approach the research process: It begins with identifying a meaningful problem, proposing a hypothesis, and then testing it through rigorous experimentation and validation. This framework has shaped the way I think, not just about science, but about problem-solving in general.

What is the Purdue research environment like?

One unique aspect of our department is that all PhD students are required to serve as teaching assistants. I found it to be a great opportunity to gain mentoring experience — especially valuable for those considering academic careers. Publishing is also a core part of our program, and most students graduate with several peer-reviewed publications. Many of us are co-inventors on at least one patent, though not all have reached commercialization. I’ve been fortunate to receive university fellowships and departmental awards. It’s always rewarding to have your work recognized.

What advice might you give to other students deciding where to attend graduate school?

If you're looking for a place where you can deeply focus on research, Purdue is an excellent choice. Being in a smaller town means fewer distractions and a slower pace, which can be an advantage for research-intensive work. That said, West Lafayette still offers plenty of things to do — from sports events to the annual Purdue Grand Prix. You can even take flight lessons at the Purdue airport!

What about the future? What are your goals; what are you looking to accomplish in this field?

While I initially planned to pursue a postdoctoral position and an eventual faculty role, I’ve begun to pivot toward the semiconductor industry. I aim to leverage my expertise in materials science and microstructural characterization to bridge research and industry, driving innovation and contributing to technological advancement in semiconductor manufacturing.

What about after hours; what do you like to do?

I work out regularly — it helps boost my confidence and focus. I also spend time as a licensed soccer referee in the state of Indiana. I used to play, but I wasn’t particularly skilled. Becoming a referee has been a great way for me to stay involved in the sport I love from a different perspective.