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<p>Additive manufacturing (AM) of high-entropy alloys (HEAs) typically involves creating chemically homogeneous ingots through repeated melting before atomising them for AM, or by combining elemental powders to form the HEA in situ. In this study, we demonstrate an alternative approach: mixing existing alloy powders in proportion, which allows for recycling alloy powders and supports a circular economy through HEA development. Specifically, we mixed powders of stainless steel 316L and Tribaloy® T-900 to create a non-equiatomic, silicon-strengthened CrFeCoNiMo HEA, which was printed using directed-energy deposition laser-beam/metal (DED-LB/M). This HEA displayed a primary face-centred cubic solid-solution phase, with inter-dendritic intermetallic phases (<i>σ</i> and <i>µ</i>), achieving a compressive yield strength of 697 MPa and ductility of 28.1% at room temperature. After homogenising at 1100&#xa0;°C for 8&#xa0;h followed by furnace cooling, the inter-dendritic <i>σ</i> and <i>µ</i> phases transformed into globular Laves phase, resulting in a yield strength of 716&#xa0;MPa and ductility of 34.8% with good work hardenability. Potentiodynamic polarisation in 3.5 wt.% NaCl solution showed corrosion performance comparable to DED-LB/M 316L, which had a much lower yield strength (334&#xa0;MPa). This underscores our HEA’s potential in similar environments where higher strength is essential. Notably, this work offers an alternative approach to designing and manufacturing HEAs in a circular economy.</p>

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Design and additive manufacture of non-equiatomic CrFeCoNiMo high-entropy alloys using alloy powders

  • 期刊论文

  • 发表日期：

    2025年10月27日

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  • Kazuki Kuhlmann,
  • Kun Vanna Yang,
  • Ali Ramezannejad,
  • Ecio Bosi,
  • Andrew Siao Ming Ang,
  • Robert Simon Wilson,
  • Mark Styles,
  • David Ritchie,
  • Andrey Molotnikov,
  • Ma Qian

摘要

Additive manufacturing (AM) of high-entropy alloys (HEAs) typically involves creating chemically homogeneous ingots through repeated melting before atomising them for AM, or by combining elemental powders to form the HEA in situ. In this study, we demonstrate an alternative approach: mixing existing alloy powders in proportion, which allows for recycling alloy powders and supports a circular economy through HEA development. Specifically, we mixed powders of stainless steel 316L and Tribaloy® T-900 to create a non-equiatomic, silicon-strengthened CrFeCoNiMo HEA, which was printed using directed-energy deposition laser-beam/metal (DED-LB/M). This HEA displayed a primary face-centred cubic solid-solution phase, with inter-dendritic intermetallic phases (σ and µ), achieving a compressive yield strength of 697 MPa and ductility of 28.1% at room temperature. After homogenising at 1100 °C for 8 h followed by furnace cooling, the inter-dendritic σ and µ phases transformed into globular Laves phase, resulting in a yield strength of 716 MPa and ductility of 34.8% with good work hardenability. Potentiodynamic polarisation in 3.5 wt.% NaCl solution showed corrosion performance comparable to DED-LB/M 316L, which had a much lower yield strength (334 MPa). This underscores our HEA’s potential in similar environments where higher strength is essential. Notably, this work offers an alternative approach to designing and manufacturing HEAs in a circular economy.