Ultra strong FCC structured Ni8Cr4Co4Fe6W2 high entropy alloys with high strength and ductility by laser powder bed fusion

The high entropy alloys (HEAs) are widely used in high temperature service environment (such as aviation engine blades) with bright application potential in additive manufacturing. Laser powder bed fusion (LPBF) is technology currently offers the best reproducibility and dimensional accuracy for part production. The unique atomic lattice structure of HEA makes its plastic deformation mechanism different from that of traditional dilution alloy, resulting in the strengthening effect of face-centered cubic high-entropy alloy different from that of traditional metal alloy materials. In this paper, Ni8Cr4Co4Fe6W2 was designed by means of composition control. Its spherical powders with uniform composition were successfully prepared by high temperature remelting spheroidization (PHTR) method, compared with gas atomization (GA) method. The strain rate sensitivity m values of GA-Selective Laser Melting and PHTR-Selective Laser Melting samples were 0.030 and 0.027, respectively. The hardness of Ni8Cr4Co4Fe6W2 high-entropy alloy showed a trend of continuous increase with the decrease of grain size, while the elastic modulus didn’t change much (PHTR-SLM is 193 Gpa and GA-SLM is 189 Gpa). The simulated value of the contact stress decreased by 23% compared with the theoretical value. The contact radius increased with the increase of plastic deformation in addition to the reduction of contact pressure. The printing sample value of the elongation, yield strength (YS) and Ultimate Tensile Strength (UTS) on PHTR-SLM has increased by 39.6%, 33.7% and 25.9%, respectively in additive manufacturing, compared to GA-SLM. The ability to produce refractory HEAs through PHTR method will make it possible to manufacture complex geometry shapes at a reasonable cost.