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Constructing Hetero-Microstructures in Additively Manufactured High-Performance High-Entropy Alloys.
Yuanshu Zhao1,2,3, Zhibin Wu1,2,3, Yongkun Mu1,2,3
1State Key Laboratory of Materials for Advanced Nuclear Energy, Shanghai University, Shanghai 200444, China.
Entropy (Basel, Switzerland)
|September 27, 2025
Summary
Additive manufacturing (AM) enables precise control over heterogeneous microstructures in high-entropy alloys (HEAs). This approach enhances both strength and ductility, paving the way for advanced structural materials.
Area of Science:
- Materials Science
- Metallurgy
- Additive Manufacturing
Background:
- High-entropy alloys (HEAs) offer exceptional mechanical properties and thermal stability for extreme environments.
- Balancing strength and ductility in traditional alloy design is challenging.
- Heterogeneous microstructures are key to overcoming limitations in traditional alloy design.
Purpose of the Study:
- To review the use of additive manufacturing (AM) in engineering heterogeneous microstructures for high-performance HEAs.
- To examine the multiscale heterogeneities induced by AM processes like selective laser melting (SLM) and electron beam melting (EBM).
- To discuss the role of these heterostructures in improving strength-ductility synergy and work-hardening behavior.
Main Methods:
- Systematic review of recent advancements in AM for HEA microstructure engineering.
- Analysis of thermal cycling effects inherent to AM processes (SLM, EBM).
- Examination of structure-property relationships in AM-fabricated heterogeneous HEAs.
Main Results:
- AM techniques enable precise fabrication of complex, spatially controlled, and non-equilibrium microstructures in HEAs.
- AM-induced heterogeneities significantly enhance the synergistic combination of strength and ductility.
- Engineered heterostructures improve the work-hardening characteristics of HEAs.
Conclusions:
- Additive manufacturing provides an ideal platform for creating tailored heterogeneous HEAs.
- This approach facilitates a shift towards microstructural control-driven alloy design.
- AM integration offers a pathway for developing next-generation structural materials with superior, multi-attribute performance.
