Additive manufacturing of defect-free TiZrNbTa refractory high-entropy alloy with enhanced elastic isotropy via in-situ alloying of elemental powders

Laser powder-bed fusion (L-PBF) additive manufacturing presents ample opportunities to produce net-shape parts. The complex laser-powder interactions result in high cooling rates that often lead to unique microstructures and excellent mechanical properties. Refractory high-entropy alloys show great...

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Bibliographic Details
Published in:Communications materials 2024-02, Vol.5 (1), p.14-12, Article 14
Main Authors: Mooraj, Shahryar, Kim, George, Fan, Xuesong, Samuha, Shmuel, Xie, Yujun, Li, Tianyi, Tiley, Jaimie S., Chen, Yan, Yu, Dunji, An, Ke, Hosemann, Peter, Liaw, Peter K., Chen, Wei, Chen, Wen
Format: Article
Language:English
Subjects:
639/166/988
639/301/1023/1026
Additive manufacturing
Alloy powders
Alloy systems
Alloying elements
Alloys
Chemistry and Materials Science
Cooling rate
Crack sensitivity
Defects
Entropy
High entropy alloys
High temperature
Isotropy
Manufacturing
MATERIALS SCIENCE
Mechanical properties
Melting
Net shape
Refractory alloys
Refractory materials
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Summary:Laser powder-bed fusion (L-PBF) additive manufacturing presents ample opportunities to produce net-shape parts. The complex laser-powder interactions result in high cooling rates that often lead to unique microstructures and excellent mechanical properties. Refractory high-entropy alloys show great potential for high-temperature applications but are notoriously difficult to process by additive processes due to their sensitivity to cracking and defects, such as un-melted powders and keyholes. Here, we present a method based on a normalized model-based processing diagram to achieve a nearly defect-free TiZrNbTa alloy via in-situ alloying of elemental powders during L-PBF. Compared to its as-cast counterpart, the as-printed TiZrNbTa exhibits comparable mechanical properties but with enhanced elastic isotropy. This method has good potential for other refractory alloy systems based on in-situ alloying of elemental powders, thereby creating new opportunities to rapidly expand the collection of processable refractory materials via L-PBF. Refractory high-entropy alloys are attractive for high-temperature applications, but are challenging to process. Here, a method is shown for identifying a processing window that allows the additive manufacturing of a TiZrNbTa refractory alloy with a low defect content and mechanical properties comparable to as-cast samples.
ISSN:2662-4443
2662-4443
DOI:10.1038/s43246-024-00452-0