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Plasma Arc Robot for Direct Wall High-Entropy Alloy Additive Manufacturing
Wei Wu1, Haoran Wang1, Yani Hu1
1School of Automobile and Transportation Engineering, Guangdong Polytechnic Normal University, Guangzhou 510665, China.
Materials (Basel, Switzerland)
|January 28, 2026
Summary
Plasma arc additive manufacturing of AlCoCrFeNi high-entropy alloys shows potential for aerospace applications. This method refines structures and enhances mechanical properties, enabling precise control and uniform hardness in thin-walled components.
Area of Science:
- Materials Science
- Metallurgy
- Additive Manufacturing
Background:
- High-entropy alloys (HEAs) offer superior properties but fabricating complex structures like thin walls remains challenging.
- Plasma arc additive manufacturing (PAAM) is a promising technique for metallic component fabrication.
Purpose of the Study:
- To investigate the mechanical properties and microstructure of AlCoCrFeNi thin-walled HEAs produced by PAAM.
- To evaluate the feasibility and future development of PAAM for thin-walled HEA applications.
Main Methods:
- Fabrication of 50-layer AlCoCrFeNi HEA specimens using PAAM with oscillation.
- Analysis of sample appearance, microstructure, Vickers microhardness, and tensile properties.
- Comparison of transverse and longitudinal tensile specimens relative to the deposition direction.
Main Results:
- Similar proportions of columnar and intergranular dendrites observed, with uniform cross-section columnar dendrites.
- Vickers microhardness increased from edges towards the center.
- Longitudinal specimens showed more regular structures and increased elongation with height, while transverse specimens exhibited stress concentration.
Conclusions:
- PAAM enables precise control over composition and microstructure in thin-walled HEAs.
- The technique offers potential for uniform hardness distribution and enhanced mechanical properties.
- PAAM is a viable manufacturing method for thin-walled HEAs with applications in aerospace and energy sectors.
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