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High-entropy alloys (HEAs), characterized by five or more principal elements leading to high configurational entropy, have emerged as advanced structural materials due to their exceptional strength, ductility, corrosion resistance, and high-temperature stability. Conventional manufacturing techniques like casting and powder metallurgy often lead to coarse grains, elemental segregation, and restricted design flexibility. The paper reviews the application of additive manufacturing (AM), specifically focusing on Selective Lase Melting (SLM) and Laser Metal Deposition (LMD) as transformative fabrication methods for HEAs. AM facilitates rapid solidification, refined microstructures, minimized segregation, and near-net-shape production of intricate HEA components. Systems like CoCrFeNi and CoCrFeMnNi produced through AM display columnar grains, cellular–dendritic structures, dense dislocation networks, and exceptional cryogenic mechanical properties. AlxCoCrFeNi alloys exhibit adjustable FCC, BCC, and B2 phases based on Al content, allowing for significant control over hardness and tensile characteristics. Refractory HEAs such as TaNbHfZrTi demonstrate stable BCC phases with outstanding high-temperature mechanical strength. Factors like volumetric energy density, cooling rate, and feedstock type play a crucial role in influencing microstructure development. The mechanical performance of AM-processed HEAs generally exceeds that of traditionally cast alloys due to grain refinement, solid-solution strengthening, and precipitate formation. Despite considerable advancements, challenges persist in predicting phase stability, managing defects, and scaling up production. Overall, the synergistic combination of AM`s processing capabilities and the unique properties of HEAs opens new avenues for designing advanced materials suitable for extreme and demanding industrial applications.

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Tailoring Microstructure and Mechanical Performance of HEAs via 3D Printing Technologies

  • 章节

  • 发表日期：

    2026年

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  • Prince Raj,
  • Ankur Chaurasia,
  • Sandeep Kumar Singh,
  • Akarsh Verma

摘要

High-entropy alloys (HEAs), characterized by five or more principal elements leading to high configurational entropy, have emerged as advanced structural materials due to their exceptional strength, ductility, corrosion resistance, and high-temperature stability. Conventional manufacturing techniques like casting and powder metallurgy often lead to coarse grains, elemental segregation, and restricted design flexibility. The paper reviews the application of additive manufacturing (AM), specifically focusing on Selective Lase Melting (SLM) and Laser Metal Deposition (LMD) as transformative fabrication methods for HEAs. AM facilitates rapid solidification, refined microstructures, minimized segregation, and near-net-shape production of intricate HEA components. Systems like CoCrFeNi and CoCrFeMnNi produced through AM display columnar grains, cellular–dendritic structures, dense dislocation networks, and exceptional cryogenic mechanical properties. AlxCoCrFeNi alloys exhibit adjustable FCC, BCC, and B2 phases based on Al content, allowing for significant control over hardness and tensile characteristics. Refractory HEAs such as TaNbHfZrTi demonstrate stable BCC phases with outstanding high-temperature mechanical strength. Factors like volumetric energy density, cooling rate, and feedstock type play a crucial role in influencing microstructure development. The mechanical performance of AM-processed HEAs generally exceeds that of traditionally cast alloys due to grain refinement, solid-solution strengthening, and precipitate formation. Despite considerable advancements, challenges persist in predicting phase stability, managing defects, and scaling up production. Overall, the synergistic combination of AM`s processing capabilities and the unique properties of HEAs opens new avenues for designing advanced materials suitable for extreme and demanding industrial applications.