Exploring Elemental Powder Approach for Making Al and Ti Containing High-Entropy Alloys by Powder Bed Fusion

Abstract

This research aimed to produce high-entropy alloys (HEA), namely Mn–Fe–Co–Ni + 5Al and Mn–Fe–Co–Ni + 5Al + 5Ti, through the Powder Bed Fusion technique using elemental powders. Alloy composition has been selected to achieve a HEA matrix with strengthening intermetallic precipitates. Thermo-Calc software has been used to predict solidification behavior and phase stability for non-equilibrium conditions. The experiment involved the execution of an additive manufacturing process with a laser working in point-by-point exposure mode to produce samples using varying laser power and exposure time. The samples underwent investigation via macroscopic examination, porosity analysis, scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction, and hardness testing. Results have shown that processing parameters and alloy constituents directly influenced processability and sample traits. What is more, a high-energy laser beam introduction to the material during the process has helped mitigate the formation of large Ti or Al oxides. In addition, EDS analysis indicated that higher Volumetric Energy Density values enhanced the uniformity of chemical composition, indicating that homogeneity can be achieved by selecting appropriate melting parameters. The results clearly show that these alloys can be successfully (by means of porosity and homogeneity) manufactured from elemental powders via the powder bed fusion technique.