Effect of Laser Energy Density on Microstructures and Properties of Additively Manufactured AlCoCrFeNi2.1 Eutectic High-Entropy Alloy

doi:10.1007/s40195-024-01783-0

Abstract

Abstract:

In the present study, AlCoCrFeNi_2.1 eutectic high-entropy alloy (EHEA) has been fabricated by laser melting deposition (LMD). The influence of laser energy density on microstructures, wear resistance and corrosion resistance of the alloy was systematically explored. The results indicate that the AlCoCrFeNi_2.1 EHEA exhibited lamellar eutectic microstructures with alternating FCC and BCC phases. With the increase in laser energy density, the alloy grain size, interlamellar spacing, and volume fraction of the FCC phase increased, while the hardness of the alloy decreased. Meanwhile, the tribological performance of the alloy deteriorated with increasing laser energy density, and the combined effects of abrasive wear and adhesive wear gradually became significant. In addition, increasing laser energy density from 18.2 to 25 J/mm² resulted in the increase in corrosion current density of the AlCoCrFeNi_2.1 EHEA from 6.36 × 10⁻⁸ to 3.02 × 10⁻⁷ A/cm² and the negative shift of corrosion potential from − 211 to − 292 mV (SCE). In summary, reducing laser energy density improved the wear and corrosion performance of the additively manufactured AlCoCrFeNi_2.1 EHEA.

Key words: Additive manufacturing, AlCoCrFeNi_2.1 eutectic high-entropy alloy, Wear resistance, Corrosion resistance

Lingxiao Du, Hang Ding, Yun Xie, Li Ji, Wanbin Chen, Yunze Xu. Effect of Laser Energy Density on Microstructures and Properties of Additively Manufactured AlCoCrFeNi_2.1 Eutectic High-Entropy Alloy[J]. Acta Metallurgica Sinica (English Letters), 2025, 38(2): 233-244.

Figures/Tables 16

Fig. 1 a Morphology of AlCoCrFeNi2.1 powders; b particle size distribution; c cross-sectional macrographs of the samples prepared using different laser energy densities

Fig. 2 a Schematic representation of the laser scan strategy; b cross-sectional macrograph of the sample prepared using laser energy density of 15.9 J/mm.2

Table 1 LMD processing parameters

Sample	Scanning speed (mm/min)	Spot diameter (mm)	Laser power (W)	Energy density (J/mm²)
E₁	1200	2.2	800	18.2
E₂	1200	2.2	900	20.5
E₃	1200	2.2	1000	22.7
E₄	1200	2.2	1100	25

Fig. 3 XRD patterns of the samples prepared with different laser energy densities

Fig. 4 Inverse pole figure maps of the samples prepared with different laser energy densities: a 18.2 J/mm2, b 20.5 J/mm2, c 22.7 J/mm2, d 25 J/mm.2

Fig. 5 SEM morphologies of the samples prepared with different laser energy densities: a 18.2 J/mm2, b 20.5 J/mm2, c 22.7 J/mm2, d 25 J/mm.2

Table 2 EDS results of the samples prepared with different laser energy densities (at.%)

Phase	Sample	Al	Co	Fe	Cr	Ni
BCC	E₁	31.4	7.9	8.4	12.7	39.6
	E₂	29.8	9.2	9.2	13.5	38.3
	E₃	29.0	10.0	9.4	13.8	37.8
	E₄	28.3	9.8	10.0	14.1	37.8
FCC	E₁	12.8	19.4	17.1	18.8	31.9
	E₂	13.8	18.8	16.6	18.4	32.4
	E₃	14.0	18.6	16.7	18.6	32.1
	E₄	13.2	18.5	17.3	18.6	32.4

Fig. 6 Interlamellar spacing of the samples prepared with different laser energy densities

Fig. 7 Volume fractions of the FCC and BCC phases of the samples prepared with different laser energy densities

Fig. 8 Average microhardness of the samples prepared with different laser energy densities

Fig. 9 a Friction coefficient curves, b wear rates of the samples prepared with different laser energy densities

Fig. 10 a 3D morphologies, b outlines of wear surfaces of the samples prepared with different laser energy densities

Fig. 11 Wear morphologies of the samples prepared with different laser energy: a 18.2 J/mm2, b 20.5 J/mm2, c 22.7 J/mm2, d 25 J/mm2

Table 3 EDS results of the marked regions in Fig. 11 (at.%)

Region	Al	Co	Cr	Fe	Ni	O
A	8.8	6.9	7.0	6.0	13.6	57.7
B	9.1	6.9	6.8	5.8	14.0	57.4
C	10.7	7.9	6.3	5.9	15.9	53.3
D	12.3	11.4	10.1	8.9	21.7	35.6

Fig. 12 Polarization curves of the samples in 3.5 wt% NaCl solution under different laser energy densities

Table 4 Electrochemical parameters obtained by potentiodynamic polarization tests for the samples prepared with different laser energy densities

Sample	E_corr (mV)	i_corr (A·cm⁻²)	E_pit (mV)
E₁	− 211	6.36 × 10⁻⁸	226
E₂	− 234	2.62 × 10⁻⁷	142
E₃	− 265	2.89 × 10⁻⁷	195
E₄	− 292	3.02 × 10⁻⁷	154

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