Optimization of high-entropy alloys (HEAS) for lightweight automotive components: Design, fabrication, and performance enhancement

Abstract

This paper provides a comprehensive analysis of the integration and optimization of High-Entropy Alloys (HEAs) for automotive applications, emphasizing their potential to enhance vehicle performance through superior strength-to-weight ratios, thermal stability, and corrosion resistance. Drawing on methodologies from life cycle assessments (LCAs) and insights into fuel savings achieved through lightweight design, the study explores the criteria for selecting HEAs, including composition design, thermal stability, and manufacturing compatibility. It highlights the importance of advanced Computer-Aided Design (CAD) and simulation techniques in optimizing HEA components, ensuring they meet the rigorous demands of automotive applications. The paper also examines fabrication techniques such as arc melting, casting, and additive manufacturing, alongside quality control methods like Non-Destructive Testing (NDT) and mechanical performance assessments. Through case studies of HEA-based engine, structural, and safety components, the research demonstrates significant improvements in fuel efficiency, structural integrity, and safety. The discussion extends to future research directions, focusing on cost reduction, new applications in aerospace and defense, and advancements in fabrication techniques. Finally, the paper addresses sustainability considerations, including resource efficiency, recycling, and life cycle analysis, underscoring the potential of HEAs to contribute to both performance enhancement and environmental conservation in the automotive industry.