Novel Fe-rich hypo-eutectic high entropy alloy developed for laser powder bed fusion in the Al-Co-Cr-Fe-Ni-Zr system

Abstract

A novel heat resistant Fe-rich hypo-eutectic high entropy alloy (HEA) was manufactured using laser powder bed fusion (LPBF). The prealloyed Al1/4Co2Cr2Fe6Ni3/2Zr powder was characterized and processed using different preheating temperatures (650°C, 700°C and 800°C). The as-built microstructure showed dissimilar morphologies throughout the melt pool, with eutectic grains of ultra fine lamella spacing (λ≈25 nm) inside the core regions, and coarser dendritic and globulitic growth patterns at the interlayer boundaries (ILBs). An annealing treatment at 1000°C for 6 h yielded a homogenous composite microstructure of a Fe-rich matrix with ∼40 % of fine dispersed Zr-rich intermetallic (IM) phases of submicron size. Synchrotron high energy x-ray diffraction (HEXRD) revealed M2Zr Laves (M = Co, Fe, Ni) as the main IM for the as-built condition and the additional growth of M23Zr6 upon annealing. Further HEXRD in-situ high temperature tests examined the lattice parameter evolution and coefficient of thermal expansion (CTE) up to 1100°C. The mechanical performance of the as-built and annealed condition was evaluated through hardness and compression testing at room temperature (RT). Additional compression testing from RT to 1000°C were conducted on the annealed condition to assess the high temperature strength and give comparison to other high temperature materials like Ni-based superalloys.