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<p>High Entropy Alloys (HEAs) have earned extensive research interest over the past two decades due to their unique compositional design and functional properties. Unlike conventional alloys based on a primary element, HEAs consist of five or more principal elements in equiatomic or near-equiatomic ratios, leading to high configurational entropy that stabilizes simple solid solution phases. Various synthesis techniques, including solid-state processing, liquid-state method, additive manufacturing, and advanced coating technologies, have been employed to fabricate HEAs with tailored properties. However, challenges persist in achieving compositional homogeneity, controlling microstructure, processing high melting point elements, and ensuring scalability. Despite these limitations, HEAs exhibit remarkable strength, enhanced hardness, thermal stability, wear resistance, and corrosion resistance, making them suitable for aerospace, energy, and biomedical applications. This review systematically analyzes the processing routes, microstructural evolution, mechanical performance, and application potential of HEAs. The insights aim to guide future advancements in the design and scalable manufacturing of high-performance HEAs.</p>

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Processing Routes, Functional Properties, and Potential Applications of High Entropy Alloys: A Review

  • 期刊论文

  • 发表日期：

    2025年9月19日

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  • Samarjit Panda,
  • R. Vaira Vignesh,
  • M. Govindaraju,
  • B. Arivazhagan

摘要

High Entropy Alloys (HEAs) have earned extensive research interest over the past two decades due to their unique compositional design and functional properties. Unlike conventional alloys based on a primary element, HEAs consist of five or more principal elements in equiatomic or near-equiatomic ratios, leading to high configurational entropy that stabilizes simple solid solution phases. Various synthesis techniques, including solid-state processing, liquid-state method, additive manufacturing, and advanced coating technologies, have been employed to fabricate HEAs with tailored properties. However, challenges persist in achieving compositional homogeneity, controlling microstructure, processing high melting point elements, and ensuring scalability. Despite these limitations, HEAs exhibit remarkable strength, enhanced hardness, thermal stability, wear resistance, and corrosion resistance, making them suitable for aerospace, energy, and biomedical applications. This review systematically analyzes the processing routes, microstructural evolution, mechanical performance, and application potential of HEAs. The insights aim to guide future advancements in the design and scalable manufacturing of high-performance HEAs.