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<p>This study investigates the influence of laser process parameters on process-induced defects in additive manufacturing of equiatomic AlCoCrFeMo high-entropy alloy (HEA) via laser-beam powder bed fusion (PBF-LB), leading to enhanced densification, microstructure, and hardness of the additively manufactured parts. A full-factorial design of experiments (DOE) was performed, varying laser power (<i>P</i>: 80–120&#xa0;W) and scanning speed (<i>v</i>: 520–750&#xa0;mm/s) to examine the effect of volumetric energy density (<i>E</i><sub>v</sub>: 33.33–72.12&#xa0;J/mm<sup>3</sup>) on microstructural evolution. The results showed that the sample fabricated at 50.00&#xa0;J/mm<sup>3</sup> exhibited the highest relative density (99.14%) and microhardness (768 HV<sub>0.3</sub>), due to a reduction in lack-of-fusion pores and internal cracks with columnar grains showing a ⟨001⟩ texture. The X-ray diffraction (XRD) and electron backscattered diffraction (EBSD) analyses revealed a single-phase body-centered cubic (BCC) structure with lattice contraction in parts produced at <i>E</i><sub>v</sub> of 72.12&#xa0;J/mm<sup>3</sup>, which is attributed to volatilization of alloying elements, particularly aluminum (Al). This study provides insights into processing-structure-property relationships and could serve as a basis for future investigations into potential applications in demanding environments relevant to the aerospace and energy sectors.</p> Graphical abstract <p></p>

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Process-induced defects and microstructural characteristics of AlCoCrFeMo high entropy alloy produced by laser-beam powder bed fusion (PBF-LB)

  • 期刊论文

  • 发表日期：

    2026年8月3日

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  • Akash Vyas,
  • Ahmed Moustafa Abd-El Nabi,
  • Hanieh Ahmadi,
  • Pankaj Kumar,
  • James Hogan,
  • André McDonald,
  • Mostafa Yakout

摘要

This study investigates the influence of laser process parameters on process-induced defects in additive manufacturing of equiatomic AlCoCrFeMo high-entropy alloy (HEA) via laser-beam powder bed fusion (PBF-LB), leading to enhanced densification, microstructure, and hardness of the additively manufactured parts. A full-factorial design of experiments (DOE) was performed, varying laser power (P: 80–120 W) and scanning speed (v: 520–750 mm/s) to examine the effect of volumetric energy density (Ev: 33.33–72.12 J/mm3) on microstructural evolution. The results showed that the sample fabricated at 50.00 J/mm3 exhibited the highest relative density (99.14%) and microhardness (768 HV0.3), due to a reduction in lack-of-fusion pores and internal cracks with columnar grains showing a ⟨001⟩ texture. The X-ray diffraction (XRD) and electron backscattered diffraction (EBSD) analyses revealed a single-phase body-centered cubic (BCC) structure with lattice contraction in parts produced at Ev of 72.12 J/mm3, which is attributed to volatilization of alloying elements, particularly aluminum (Al). This study provides insights into processing-structure-property relationships and could serve as a basis for future investigations into potential applications in demanding environments relevant to the aerospace and energy sectors.

Graphical abstract