Crack Formation and Control in an AlCoCrFeNi High Entropy Alloy Fabricated by Selective Laser Melting

The equiatomic AlCoCrFeNi high entropy alloy (HEA) is prone to cracking during the additive manufacturing process due to the high cooling rates observed, which limits its application to a large extent. In this study, the selective laser melting (SLM) technique was adopted to fabricate the alloy and the mechanism of crack formation was revealed. Most importantly, a new design strategy was proposed to suppress the generation of cracks, and the optimization of the preparation process was also studied in detail. It is found that the interlaminar crack is related to the heat input at the edge of the specimen, and the internal cracks are formed by solidification cracks. Alloys without interlaminar crack can be prepared by means of combination of the side inclination angle and the process parameters. Side inclination angle optimization provides a possibility for the preparation of crack-free AlCoCrFeNi HEA by SLM.