Fabrication of bulk Al-Co-Cr-Fe-Ni high-entropy alloy using combined cable wire arc additive manufacturing (CCW-AAM): Microstructure and mechanical properties

doi:10.1016/j.jmst.2020.10.037

Abstract

Abstract:

Additive manufacturing is a very promising manufacturing method widely used in various industries. In this study, for the first time, a new type of combined cable wire (CCW) with multi-element composition has been designed and developed for arc additive manufacturing (AAM) of non-equiatomic Al-Co-Cr-Fe-Ni high-entropy alloy. CCW composed of 7 filaments and 5 elements has the advantages of high deposition efficiency, self-rotation of welding arc and energy saving capability. Thin HEA walls were fabricated under pure argon gas using cold metal transfer technology. Microstructural observations of the developed HEA reveal (i) BCC and FCC phases, (ii) Good bonding between layers and (iii) defect-free microstructure. The developed alloy exhibits high compression strength (~2.9 GPa) coupled with high elongation (~42 %) values (possess both strength and ductility). It has been identified that by varying the heat input via torch travel speed, the microstructure and mechanical properties of the HEA can be controlled. From this feasibility study, it has been proved that the innovative CCW method can be used to manufacture HEAs with CCW-AAM. Further, the study highlights the advantage of the rapid cooling involved in the CCW-AAM process which gives rise to superior mechanical properties.

Key words: Combined cable wire, Arc additive manufacturing, High-entropy alloy, Microstructure, Mechanical properties

Qingkai Shen, Xiangdong Kong, Xizhang Chen. Fabrication of bulk Al-Co-Cr-Fe-Ni high-entropy alloy using combined cable wire arc additive manufacturing (CCW-AAM): Microstructure and mechanical properties[J]. J. Mater. Sci. Technol., 2021, 74: 136-142.

Figures/Tables 11

Fig. 1. (a) Schematic of the CCW-AAM technique used to create HEA and (b) 3D model of CCW.

Table 1 Process parameters of CCW-AAM deposition of HEAs.

Sample	Current (A)	Voltage (V)	Wire feed speed (m/min)	Torch travel speed (mm/s)	Heat input (J/mm)
1	156	16.2	5.5	8	315.9
2	156	16.2	5.5	10	252.7
3	156	16.2	5.5	12	210.6

Fig. 2. Samples of Al-Co-Cr-Fe-Ni HEA fabricated using CCW-AAM: (a) 8 mm/s travel speed; (b) 10 mm/s travel speed; (c) 12 mm/s travel speed; (d) vacuum arc casting.

Table 2 Chemical compositions (at.%) of HEAs fabricated by CCW-AAM and casting.

Specimens	Al	Co	Cr	Fe	Ni
CCW-AAM	20.13 ± 0.42	17.08 ± 0.21	3.18 ± 0.21	27.18 ± 0.29	32.42 ± 0.51
Casting	22.14 ± 1.05	16.73 ± 0.37	2.96 ± 0.01	25.73 ± 0.19	32.44 ± 0.48

Fig. 3. XRD patterns of HEAs developed by casting and CCW-AAM with different travel speeds.

Fig. 4. Phase maps and grain size distribution within the HEA: (a) and (b) 8 mm/s travel speed, (c) and (d) 10 mm/s travel speed, (e) and (f) 12 mm/s travel speed, (g) and (h) casting specimens.

Fig. 5. EDS map of Al-Co-Cr-Fe-Ni HEA showing elemental distribution in the BCC and FCC phases.

Fig. 6. IPF maps of the fabricated HEAs: (a) 8 mm/s travel speed, (b) 10 mm/s travel speed, (c) 12 mm/s travel speed and (d) casting specimens.

Fig. 7. Microhardness of the HEAs fabricated by CCW-AAM and casting specimens: (a) variation in hardness curve; (b) average hardness curve.

Fig. 8. Compressive test results of HEA prepared by CCW-AAM and casting process: (a) stress-strain curves; (b) variation of compression mechanical properties (YS, UTS and EL) with test specimens.

Table 3 Room temperature compression mechanical properties.

Alloy	σ_y (MPa)	σ_max (MPa)	ε_p (%)
AlCoCrFeNi [45]	1209	2003	23.0
Al_0.6CoFeNiCr_0.4 [46]	668	1324	39.0
CoCrCuFeNiTi_0.8 [11]	1042	1848	2.1
AlCoCrFeNiCu [47]	1169	1918	17.9
This work (CCW-AAM)	816	2835	41.8
This work (Casting)	887	2723	37.4

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