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<p>High-entropy alloys (HEAs) constitute a new class of metallic materials with unique properties that have attracted increasing research interest in recent years. However, the fabrication process of HEAs through conventional manufacturing techniques suffers from significant limitations due to their complex physical metallurgy, which remains insufficiently understood. Additive manufacturing (AM), with its high flexibility and process control, provides a powerful platform for tailoring HEA compositions and microstructures. The integration of HEAs with AM, therefore, offers a promising pathway to advance fundamental understanding and enable novel applications of these alloys. This review summarizes the various AM techniques (Laser Powder Bed Fusion (LPBF), Selective Laser Melting (SLM), Direct Energy Deposition (DED), Electron Beam Melting (EBM), Binder Jetting (BJ), Material Extrusion (ME), and Wire Arc Additive Manufacturing (WAAM)/Wire-powder Arc Additive Manufacturing process) in the fabrication of HEAs, with emphasis on their influence on microstructure and mechanical performance. Due to the rapid solidification inherent in AM processes, AM-fabricated HEAs typically exhibit refined microstructures compared to their cast counterparts, resulting in enhanced yield strength and ductility. Despite these advantages, challenges persist in relation to defect formation, process optimization, and compositional control, underscoring the need for systematic studies to address existing limitations and inform future research directions in AM-HEAs.</p>

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Additive manufacturing of high-entropy alloys (AM-HEAs): a comprehensive review of processing methods, microstructure, mechanical properties, and challenges

  • 期刊论文

  • 发表日期：

    2026年7月31日

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  • Manoj Mugale,
  • Sainand Jadhav,
  • Amit Choudhari,
  • Akash Belure,
  • Suhas Alkunte,
  • Sanoj Karki,
  • Satyavan Digole,
  • Tushar Borkar

摘要

High-entropy alloys (HEAs) constitute a new class of metallic materials with unique properties that have attracted increasing research interest in recent years. However, the fabrication process of HEAs through conventional manufacturing techniques suffers from significant limitations due to their complex physical metallurgy, which remains insufficiently understood. Additive manufacturing (AM), with its high flexibility and process control, provides a powerful platform for tailoring HEA compositions and microstructures. The integration of HEAs with AM, therefore, offers a promising pathway to advance fundamental understanding and enable novel applications of these alloys. This review summarizes the various AM techniques (Laser Powder Bed Fusion (LPBF), Selective Laser Melting (SLM), Direct Energy Deposition (DED), Electron Beam Melting (EBM), Binder Jetting (BJ), Material Extrusion (ME), and Wire Arc Additive Manufacturing (WAAM)/Wire-powder Arc Additive Manufacturing process) in the fabrication of HEAs, with emphasis on their influence on microstructure and mechanical performance. Due to the rapid solidification inherent in AM processes, AM-fabricated HEAs typically exhibit refined microstructures compared to their cast counterparts, resulting in enhanced yield strength and ductility. Despite these advantages, challenges persist in relation to defect formation, process optimization, and compositional control, underscoring the need for systematic studies to address existing limitations and inform future research directions in AM-HEAs.