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The main objective of this chapter is to provide a comprehensive overview of the synergistic relationship between Additive Manufacturing (AM) and high-entropy alloys (HEAs). AM is a transformative layer-by-layer fabrication technique that offers unparalleled design freedom and the ability to produce complex geometries. The chapter explores key AM methods, including Laser Powder Bed Fusion (LPBF), Directed Energy Deposition (DED), and WAAM, highlighting how the unique thermal histories and rapid solidification rates of each process profoundly influence material characteristics. HEAs are multi-principal element alloys stabilized by a high configurational entropy. The central focus of the chapter is to elucidate the critical importance of studying the microstructural evolution in AM-processed HEAs. The non-equilibrium conditions of AM result in unique microstructures, such as fine-grained or columnar substructures and metastable phases, which are fundamentally different from those of conventionally processed alloys. This chapter establishes a clear process-structure–property relationship, enabling the predictive design and optimization of AM-fabricated HEA components for advanced applications.

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Additive Manufacturing of HEAs: Microstructure Evolution and Mechanical Response

  • 章节

  • 发表日期：

    2026年

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  • Dheeraj Gunwant,
  • Ashwani Kumar

摘要

The main objective of this chapter is to provide a comprehensive overview of the synergistic relationship between Additive Manufacturing (AM) and high-entropy alloys (HEAs). AM is a transformative layer-by-layer fabrication technique that offers unparalleled design freedom and the ability to produce complex geometries. The chapter explores key AM methods, including Laser Powder Bed Fusion (LPBF), Directed Energy Deposition (DED), and WAAM, highlighting how the unique thermal histories and rapid solidification rates of each process profoundly influence material characteristics. HEAs are multi-principal element alloys stabilized by a high configurational entropy. The central focus of the chapter is to elucidate the critical importance of studying the microstructural evolution in AM-processed HEAs. The non-equilibrium conditions of AM result in unique microstructures, such as fine-grained or columnar substructures and metastable phases, which are fundamentally different from those of conventionally processed alloys. This chapter establishes a clear process-structure–property relationship, enabling the predictive design and optimization of AM-fabricated HEA components for advanced applications.