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Additively Manufactured Lightweight and Hard High-Entropy Alloys by Thermally Activated Solvent Extraction

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Abstract

We introduce a scalable thermally activated solvent extraction based additive manufacturing process to produce lightweight, yet high-hardness, multicomponent alloys. The cost-effective process involves layer-wise curing a slurry composed of AlCoCrFeNi high-entropy alloy powder and a transparent ultraviolet-sensitive photopolymer, by stereolithography 3D printing followed by sintering. The alloy pellets assume a density of 4.3 g/cm3 and hardness of 400 HV with a BCC/FCC multiphase microstructure. A broad distribution in the particle sizes of the alloy powder augments the manufacturing process because the smaller particles operate as fillers to weld the larger ones. The relatively higher surface energy of the smaller particles limits the activation energy required for the onset of particulate diffusion that instigates the necking. Microscopic characterization reveals passivating surface oxides on the powder particles fabricating an alloy part suitable for harsh environments.

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The authors will make available, upon request, the data used in the applications described in this work. It is understood that the data provided will not be for commercial use.

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Acknowledgements

The research was supported by the National Science Foundation (NSF) through the award CMMI-1944040.

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  1. Department of Mechanical Engineering & Mechanics, Lehigh University, 19 Memorial Drive West, Bethlehem, PA, 18015, USA

    Prince Sharma, Chayan Das, Praveen Sreeramagiri & Ganesh Balasubramanian

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PS: Methodology, Formal Analysis, Investigation, Validation, Writing—Original Draft, Writing—Review & Editing; CD: Methodology, Investigation; PS: Methodology, Validation, Writing—Review & Editing; GB: Formal Analysis, Investigation, Writing—Review & Editing, Supervision, Funding Acquisition.

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Correspondence to Ganesh Balasubramanian.

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Sharma, P., Das, C., Sreeramagiri, P. et al. Additively Manufactured Lightweight and Hard High-Entropy Alloys by Thermally Activated Solvent Extraction. High Entropy Alloys & Materials (2024). https://doi.org/10.1007/s44210-024-00029-z

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