Impact of Conventional and Laser-Assisted Machining on the Microstructure and Mechanical Properties of Ti-Nb-Cr-V-Ni High-Entropy Alloy Fabricated with Directed Energy Deposition

The high-entropy alloy (HEA) has recently attracted significant interest due to its novel alloy design concept and exceptional mechanical properties, which may exhibit either a single or multi-phase structure. Specifically, refractory high-entropy alloys (RHEA) composed of titanium, niobium, and nickel-based HEA demonstrate remarkable mechanical properties at elevated temperatures. Additive manufacturing (AM), specifically Direct Energy Deposition (DED), is efficient in fabricating high-entropy alloys (HEA) owing to its fast-cooling rates, which promote uniform microstructures and reduce defects. This study involved the fabrication of the Ti33Nb28Cr11V11Ni17 (Ti-Nb-Cr-V-Ni) RHEA utilizing DED. Additionally, the post-processing of the fabricated alloy is conducted using conventional machining (CM) and laser-assisted machining (LAM). The results indicate thermal conductivity and specific heat increased, whereas tensile strength reduced with rising temperature. Significant softening was observed above 800 °C, resulting in a considerable decrease in tensile strength. Furthermore, the LAM caused material softening and reduced the cutting force by 60.0% relative to CM. Furthermore, the chemical composition of Ti-Nb-Cr-V-Ni remained unaffected even after post-processing with CM and LAM. The research indicates that post-processing with LAM is essential for developing resilient RHEA for practical use.