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Recent Advances in Selective Laser Melting of Cobalt-Free Eutectic High-Entropy Alloys: Design, Microstructure, and
Xiaojun Tan1, Xuyun Peng1, Wei Tan1
1Guangdong Engineering Center for Intelligent Sensing and Flexible Manufacturing, Sino-German Intelligent Manufacturing School, Shenzhen City Polytechnic, Shenzhen 518116, China.
Micromachines
|May 27, 2026
Summary
Cobalt-free eutectic high-entropy alloys (EHEAs) processed by Selective Laser Melting (SLM) offer superior strength and ductility. SLM enables fine microstructures, overcoming limitations of traditional methods for advanced structural applications.
Area of Science:
- Materials Science
- Metallurgy
- Additive Manufacturing
Background:
- Strategic shift to reduce reliance on critical raw materials.
- Cobalt-free eutectic high-entropy alloys (EHEAs) are crucial for high-performance structural applications.
- Selective Laser Melting (SLM) offers unique processing capabilities.
Purpose of the Study:
- Elucidate the relationship between Co-free alloy design and SLM non-equilibrium solidification.
- Evaluate design principles for Al-Cr-Fe-Ni and related Co-free EHEA systems.
- Provide a roadmap for precision manufacturing of EHEAs.
Main Methods:
- Systematic review of synergistic effects between alloy design and SLM.
- Analysis of ultra-high cooling rates (10^5-10^8 K/s) in SLM.
- Evaluation of Al-Cr-Fe-Ni and related alloy systems.
Main Results:
- SLM refines eutectic lamellae to sub-micron scale (<300 nm), suppressing macro-segregation.
- SLM-processed Co-free EHEAs achieve yield strengths >1000 MPa and UTS >1300 MPa.
- Tensile elongations >10% maintained, with critical processing windows identified for density and crack mitigation.
Conclusions:
- SLM enables significant improvements in mechanical properties of Co-free EHEAs compared to conventional methods.
- Quantitative roadmap provided for cost-effective, high-performance EHEA manufacturing.
- Bridging the gap between alloy design and industrial additive manufacturing.
