29 January 2024 | Punit Kumar, Sheng Huang, David H. Cook, Kai Chen, Upadrasta Ramamurty, Xipeng Tan & Robert O. Ritchie
This study presents a high-entropy alloy, Al0.5CrCoFeNi, produced using laser powder-bed fusion (LPBF), a "bottom-up" additive manufacturing process. The resulting microstructure is a nano-bridged honeycomb structure consisting of a face-centered cubic (fcc) matrix and an interwoven hexagonal B2 phase. This unique microstructure enhances the material's strength and toughness by providing a network of dislocation highways that facilitate dislocation movement away from crack tips. The LPBF process allows for the control of the microstructure, which is crucial for achieving a balance between yield strength and fracture toughness. The material exhibits a yield strength of ~729 MPa at 298 K and ~942 MPa at 77 K, with elongation to failure of ~16% at 298 K and ~27% at 77 K. The fracture toughness, measured by J-integral-based resistance curves, is ~406 kJ/m² at 298 K and ~368 kJ/m² at 77 K. The combination of high strength and toughness is superior to that of conventional wrought and high/medium-entropy alloys, highlighting the potential of "bottom-up" additive manufacturing for designing materials with intrinsic toughening.This study presents a high-entropy alloy, Al0.5CrCoFeNi, produced using laser powder-bed fusion (LPBF), a "bottom-up" additive manufacturing process. The resulting microstructure is a nano-bridged honeycomb structure consisting of a face-centered cubic (fcc) matrix and an interwoven hexagonal B2 phase. This unique microstructure enhances the material's strength and toughness by providing a network of dislocation highways that facilitate dislocation movement away from crack tips. The LPBF process allows for the control of the microstructure, which is crucial for achieving a balance between yield strength and fracture toughness. The material exhibits a yield strength of ~729 MPa at 298 K and ~942 MPa at 77 K, with elongation to failure of ~16% at 298 K and ~27% at 77 K. The fracture toughness, measured by J-integral-based resistance curves, is ~406 kJ/m² at 298 K and ~368 kJ/m² at 77 K. The combination of high strength and toughness is superior to that of conventional wrought and high/medium-entropy alloys, highlighting the potential of "bottom-up" additive manufacturing for designing materials with intrinsic toughening.