Strength-ductility balance of AlCoCrFeNi2.1 eutectic high-entropy alloy via additive manufacturing

AlCoCrFeNi2.1 eutectic high-entropy alloy (EHEA), with its distinctive heterogeneous structure, not only overcomes the drawback of insufficient strength of FCC single-phase high-entropy alloys (HEAs), but also overcomes the drawback of insufficient ductility of BCC single-phase HEAs, making it a promising candidate for engineering application. In addition, EHEAs possessing excellent castability are considered to be suitable for additive manufacturing (AM). The AlCoCrFeNi2.1 EHEA prepared by direct energy deposition (DED) exhibits a dual-phase structure consisting of FCC(L12) and BCC(B2) phases. With the increase of deposition height, its morphology transforms from columnar and dendrite structures to lamellar structure. Furthermore, the tensile strength and yield strength of the DED-ed EHEA samples increase, while the ductility decreases with the increase of deposition height. Especially, the middle region of the DED-ed samples achieves a good strength-ductility balance. The lamellar structure composed of soft FCC(L12) phase and hard BCC(B2) phase produces a hetero deformation induced (HDI) hardening, which improves the strength of the samples and promotes plastic deformation. The FCC(L12)/BCC(B2) phase interfaces not only hinder the movement of a large number of dislocations and cause dislocation pile-up, but also allow some dislocations to slip across, which helps to plastic co-deformation of two phases in the EHEA samples. This work provides useful guidance for the performance improvement of EHEAs using laser additive manufacturing.