A comparative study on microstructure, nanomechanical and corrosion behaviors of AlCoCuFeNi high entropy alloys fabricated by selective laser melting and laser metal deposition

doi:10.1016/j.jmst.2022.05.035

Abstract

Abstract:

The present study investigated the microstructure, nanomechanics, and corrosion behavior of AlCoCuFeNi high entropy alloys fabricated by selective laser melting (SLM) and laser metal deposition (LMD). The microstructure of SLM-processed specimens was mainly composed of columnar-grained BCC matrix (∼90 µm in width) and Cu-rich twinned FCC phase. The columnar grains grew epitaxially along the building direction and exhibited a strong {001} texture. In comparison, a coarse columnar-grained BCC matrix (∼150 µm in width) with a stronger 〈001〉 texture, rod-like B2 precipitates, and large core-shell structured FCC phases were formed in the LMD-processed specimens due to the higher heat accumulation effect. Consequently, the LMD-processed specimens showed a lower hardness, wear resistance, and corrosion resistance, but higher creep resistance and reduced Young's modulus than the SLM-processed specimens. Hot cracks occurred in both types of specimens, which could not be completely suppressed due to Cu segregation.

Key words: Selective laser melting, Laser metal deposition, High entropy alloys, Nanomechanics, Corrosion

Yaojia Ren, Hong Wu, Bin Liu, Yong Liu, Sheng Guo, Z.B. Jiao, Ian Baker. A comparative study on microstructure, nanomechanical and corrosion behaviors of AlCoCuFeNi high entropy alloys fabricated by selective laser melting and laser metal deposition[J]. J. Mater. Sci. Technol., 2022, 131: 221-230.

Figures/Tables 15

Fig. 1. (a) XRD patterns and (b, c) EBSD phase maps of HEA specimens processed by SLM and LMD, where red and blue represent the BCC and FCC phases, respectively, and white in Fig. 1(b) points to cracks.

Fig. 2. OM (a, b) and SE (c-f) images from the cross-sections of (a, c, e) SLM- and (b, d, f) LMD-processed AlCoCuFeNi specimens; (e, f) the enlarged views of encircled regions in (c, d).

Fig. 3. BSE images and corresponding X-ray maps of the surface of (a) SLM- and (b) LMD-processed AlCoCuFeNi specimens.

Table 1. Partitioning ratios (η) of Al, Co, Cu, Fe, and Ni in the SLM- and LMD-processed specimens.

Samples	Partitioning ratio (η)
Samples	Al	Co	Cu	Fe	Ni
SLM-processed specimen	0.66	0.72	1.83	0.58	0.74
LMD-processed specimen	1.06	1.33	4.80	1.02	1.21

Fig. 4. (a, d) IPF, (b, e) KAM, and (c, f) grain boundary orientation maps of the SLM- and LMD-processed AlCoCuFeNi specimens.

Fig. 5. Pole figures of the BCC phase for the specimens processed by SLM and LMD.

Fig. 6. TEM analysis of the AlCoCuFeNi specimen processed by SLM: (a) BF image, with the inset SAED pattern from the area encircled by the orange square, corresponding to the BCC matrix; (b) HAADF image for the area encircled by the red square in (a), and EDS line scan results across the marked red line; (c) HR-TEM image of the precipitate, with the inset FFT pattern showing a twinning relation in the FCC phase; (d) X-ray maps of Al, Co, Cu, Fe, and Ni from the area shown in (b).

Fig. 7. TEM analysis of the AlCoCuFeNi specimen processed by LMD: (a) BF image; (b) HAADF image for the area encircled by red lines in (a), and EDS line scan results across the marked red line; (c) HRTEM image of the precipitate, with the inset FFT pattern of FCC phase; (d) X-ray maps of Al, Co, Cu, Fe, and Ni from the area shown in (b).

Fig. 8. HAADF image of rod-like precipitates and the corresponding X-ray maps of Al, Co, Cu, Fe, and Ni. The inset SAED pattern corresponds to the B2 phase.

Fig. 9. (a) Load-displacement curves from nanoindentation tests; (b) hardness and Er values; (c) COF versus sliding time (s).

Fig. 10. SE images of the scratched surface for the (a) SLM- and (b) LMD-processed specimens.

Fig. 11. (a) Creep displacement-time curves; (b) ln(strain rate) versus ln(stress) plots of the SLM- and LMD-processed specimens.

Fig. 12. (a) Open circuit potential (OCP) as a function of time and (b) potentiodynamic polarization curves for the SLM- and LMD-processed AlCoCuFeNi specimens in a 3.5 wt.% NaCl solution at room temperature.

Table 2. Fitting results from polarization curves for the SLM- and LMD-processed AlCoCuFeNi specimens in a 3.5 wt.% NaCl solution.

Specimens	E_corr (V)	i_corr (μA cm⁻²)	β_a (V dec⁻¹)	β_c (V dec⁻¹)	E_pit (V)	R_p (Ω cm²)
SLM	−0.31	0.86	9.77	−13.98	−0.03	2.91 × 10⁶
LMD	−0.25	3.25	12.88	−15.16	−0.14	0.93 × 10⁶

Table 3. Hardness and corrosion behavior of various Cu-containing HEAs.

Alloys	Preparation	Phase	Hardness (HV)	Solution	E_corr (V)	i_corr (μA/cm²)
AlCoCuFe_2.1Ni [14]	GTA	BCC + FCC	407	3.5 wt.% NaCl	−0.64	8.79
AlCoCuFe_2.1Ni [14]	U-GTA	BCC + FCC	468	3.5 wt.% NaCl	−0.45	6.31
CoCrCuFeNi [57]	PTA	FCC	195	6 mol/L HCl	−0.4	1.1 × 10²
CoCrCuFeNbNi [57]	PTA	FCC + Laves	350	6 mol/L HCl	−0.4	8.9 × 10²
AlCoCuFeNi [58]	AC	BCC + B2 + FCC	391	-	-	-
AlCoCuFeNi [59]	AC	BCC + B2 + FCC	387	0.5 mol/L H₂SO₄	−0.058	7.93
AlCoCuFeNi This work	SLM	BCC + FCC	761	3.5 wt.% NaCl	−0.31	0.86
AlCoCuFeNi This work	LMD	BCC + B2 + FCC	538	3.5 wt.% NaCl	−0.25	3.25

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