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Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting

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Unravelling Microstructure Selection in an Additively Manufactured Eutectic High-Entropy Alloy.

Shengbiao Zhang¹, Chenyang Li², Shahryar Mooraj¹

¹Department of Mechanical and Industrial Engineering, University of Massachusetts, Amherst, MA, 01003, USA.

Advanced Materials (Deerfield Beach, Fla.)

|August 28, 2025

Summary

This summary is machine-generated.

Additive manufacturing (AM) of high-entropy alloys (HEAs) allows control over microstructure. Increasing solidification rates during AM of AlCrFe2Ni2 HEAs shifts solidification modes, altering properties and enabling tailored material design.

Keywords:

additive manufacturing atomistic simulation high‐entropy alloy phase transformation thermodynamic modeling

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Area of Science:

Materials Science
Metallurgy
Additive Manufacturing

Background:

High-entropy alloys (HEAs) exhibit excellent mechanical properties for structural applications.
Additive manufacturing (AM) creates unique nonequilibrium microstructures due to rapid solidification.
Understanding the interplay between AM processing, HEA microstructure, and properties is crucial.

Purpose of the Study:

Investigate the influence of solidification rate on microstructure evolution and phase transformation in laser additively manufactured AlCrFe2Ni2 HEAs.
Explore how varying laser scan speed affects solidification modes and resulting material properties.
Provide a multiscale understanding of solidification mechanisms in HEAs under nonequilibrium conditions.

Main Methods:

Laser additive manufacturing of AlCrFe2Ni2 HEAs at varying scan speeds.
Microstructural characterization to identify solidification modes (coupled eutectic, anomalous eutectic, single-phase).
Thermodynamic modeling and molecular dynamics simulations to elucidate atomic diffusion and interface stability.

Main Results:

Increasing solidification rate (via laser scan speed) transitions solidification from coupled eutectic to anomalous eutectic, and then to single-phase.
Distinct microstructures and a wide range of mechanical properties are achieved with these transitions.
Low cooling rates favor diffusion and coupled eutectic growth, while rapid cooling suppresses diffusion, promoting anomalous or single-phase solidification.

Conclusions:

Kinetic effects during rapid solidification in AM can override thermodynamic predictions for HEAs.
Additive manufacturing offers a powerful route to design HEAs with tailored microstructures and properties.
The study provides fundamental insights into solidification mechanisms in HEAs produced by AM.