Microstructure Evolution and Mechanical Properties of Al_0.5Cr_0.9FeNi_2.5V_0.2 High-Entropy Alloy Fabricated by Binder...

Binder Jetting 3D Printing (BJ3DP) offers an effective pathway for the rapid fabrication of complex high-entropy alloy (HEA) components. In this study, the macroscopic characteristics, microstructural evolution and mechanical properties of Al_0.5Cr_0.9FeNi_2.5V_0.2 HEA green parts prepared via BJ3DP were investigated under various sintering conditions. Results showed that the relative density of the sintered parts increased significantly with temperature, transitioning from a low density (<90%) at 1300-1330 °C to near-fully dense (~98%) at 1340-1350 °C. Consequently, the mechanical properties were remarkably improved. The yield strength (σ_0.2) increased from 300 MPa to 710 MPa (a 136% increase), and the ultimate tensile strength (σ_b) rose from 310 MPa to 780 MPa (a 148% increase) as sintering temperature rose from 1300 °C to 1350 °C. Microstructural analysis revealed that at lower sintering temperatures, the alloy exhibited high porosity and a non-coherent structure composed of an FCC matrix and Cr-rich BCC phase, with Al/Ni intermetallic compounds distributed around pores. Conversely, at the final sintering stage, pore closure was achieved, and a coherent structure consisting of an FCC matrix and scale-like L1₂ precipitates was formed. Optimal mechanical properties (tensile strength ≥ 700 MPa) were achieved when sintering at 1340 °C, primarily attributed to densification and precipitation strengthening.