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Abstract Laser powder-bed fusion (L-PBF) additive manufacturing presents ample opportunities to produce net-shape parts. The complex laser-powder interactions result in high cooling rates that often lead to unique microstructures and excellent mechanical properties. Refractory high-entropy alloys show great potential for high-temperature applications but are notoriously difficult to process by additive processes due to their sensitivity to cracking and defects, such as un-melted powders and keyholes. Here, we present a method based on a normalized model-based processing diagram to achieve a nearly defect-free TiZrNbTa alloy via in-situ alloying of elemental powders during L-PBF. Compared to its as-cast counterpart, the as-printed TiZrNbTa exhibits comparable mechanical properties but with enhanced elastic isotropy. This method has good potential for other refractory alloy systems based on in-situ alloying of elemental powders, thereby creating new opportunities to rapidly expand the collection of processable refractory materials via L-PBF. 

In situ neutron diffraction experiments have been performed to investigate the deformation mechanisms on CoCrFeNi high entropy alloys (HEAs) with various amounts of doped Cu. Lattice strain evolution and diffraction peak analysis were used to derive the stacking fault probability, stacking fault energy, and dislocation densities. Such diffraction analyses indirectly uncovered that a lower degree of Cu doping retained the twinning behavior in undoped CoCrFeNi HEAs, while increasing the Cu content increased the Cu clusterings which suppressed twinning and exhibited prominent dislocation strengthening. These results agree with direct observations by transmission electron microscopy.