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<p>High entropy alloys (HEAs) exhibit exceptional strength, toughness, and wear resistance, garnering significant attention from researchers worldwide. However, systematic studies on the surface machining quality of additively manufactured HEAs remain scarce. This paper presents an experimental study on the surface grinding of FeCoCrNi-based high entropy alloys. It first establishes a theoretical model for surface roughness,&#xa0;then systematically investigates&#xa0;the influence of grinding parameters (wheel speed, depth of cut, feed rate), trace elements (Al/Ti), and additive manufacturing processes (Selective Laser Melting vs. Laser Metal Deposition),&#xa0;and finally evaluates&#xa0;their effects on surface quality, including roughness, microhardness, and the thickness of the work-hardened layer. Experimental results demonstrate that grinding wheel linear speed exerts the most significant impact on surface roughness, followed by grinding depth. Increasing grinding depth elevates surface roughness, hardness, and work-hardened layer thickness, while higher grinding wheel linear speed reduces these parameters. In FeCoCrNi-based HEAs, increased Ti content under identical conditions amplifies roughness, hardness, and work-hardened layer thickness, with Ti-containing alloys exhibiting inferior machined surface quality compared to Al-containing counterparts at equivalent additive levels. Laser Metal Deposition HEAs display greater surface roughness, work hardening rate, and work-hardened layer thickness than Selective Laser Melted specimens, albeit with lower hardness. These findings provide crucial theoretical and technical support for precision machining process design and additive–subtractive hybrid manufacturing of HEAs, facilitating the design, fabrication, and application of HEA components.</p>

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Study on Grinding Surface Quality of Additive High Entropy Alloy FeCoNiCr System

  • 期刊论文

  • 发表日期：

    2026年1月28日

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  • Feng Li,
  • Xuelong Wen,
  • Xinran Zhang,
  • Linyuan Song,
  • Hongze Gui

摘要

High entropy alloys (HEAs) exhibit exceptional strength, toughness, and wear resistance, garnering significant attention from researchers worldwide. However, systematic studies on the surface machining quality of additively manufactured HEAs remain scarce. This paper presents an experimental study on the surface grinding of FeCoCrNi-based high entropy alloys. It first establishes a theoretical model for surface roughness, then systematically investigates the influence of grinding parameters (wheel speed, depth of cut, feed rate), trace elements (Al/Ti), and additive manufacturing processes (Selective Laser Melting vs. Laser Metal Deposition), and finally evaluates their effects on surface quality, including roughness, microhardness, and the thickness of the work-hardened layer. Experimental results demonstrate that grinding wheel linear speed exerts the most significant impact on surface roughness, followed by grinding depth. Increasing grinding depth elevates surface roughness, hardness, and work-hardened layer thickness, while higher grinding wheel linear speed reduces these parameters. In FeCoCrNi-based HEAs, increased Ti content under identical conditions amplifies roughness, hardness, and work-hardened layer thickness, with Ti-containing alloys exhibiting inferior machined surface quality compared to Al-containing counterparts at equivalent additive levels. Laser Metal Deposition HEAs display greater surface roughness, work hardening rate, and work-hardened layer thickness than Selective Laser Melted specimens, albeit with lower hardness. These findings provide crucial theoretical and technical support for precision machining process design and additive–subtractive hybrid manufacturing of HEAs, facilitating the design, fabrication, and application of HEA components.