Ultrahard BCC-AlCoCrFeNi bulk nanocrystalline high-entropy alloy formed by nanoscale diffusion-induced phase transition

In the current work, the BCC-AlCoCrFeNi bulk nanocrystalline high-entropy alloy (nc-HEA) with ultra-high hardness was formed by nanoscale diffusion-induced phase transition in a nanocomposite. First, a dual-phase Al/CoCrFeNi nanocrystalline high-entropy alloy composite (nc-HEAC) was prepared by a laser source inert gas condensation equipment (laser-IGC). The as-prepared nc-HEAC is composed of well-mixed FCC-Al and FCC-CoCrFeNi nanocrystals. Then, the heat treatment was used to trigger the interdiffusion between Al and CoCrFeNi nanocrystals and form an FCC-AlCoCrFeNi phase. With the increase of the annealing temperature, element diffusion intensifies, and the AlCoCrFeNi phase undergoes a phase transition from FCC to BCC structure. Finally, the BCC-AlCoCrFeNi bulk nc-HEA with high Al content (up to 50 at.%) was obtained for the first time. Excitingly, the nc-HEAC (Al-40%) sample exhibits an unprecedented ultra-high hardness of 1124 HV after annealing at 500 °C for 1 h. We present a systematic investigation of the relationship between the microstructure evolution and mechanical properties during annealing, and the corresponding micro-mechanisms in different annealing stages are revealed. The enhanced nanoscale thermal diffusion-induced phase transition process dominates the mechanical performance evolution of the nc-HEACs, which opens a new pathway for the design of high-performance nanocrystalline alloy materials.