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Abstract The far-from-equilibrium solidification during additive manufacturing often creates large residual stresses that induce solid-state cracking. Here we present a strategy to suppress solid-state cracking in an additively manufactured AlCrFe2Ni2high-entropy alloy via engineering phase transformation pathway. We investigate the solidification microstructures formed during laser powder-bed fusion and directed energy deposition, encompassing a broad range of cooling rates. At high cooling rates (104−106 K/s), we observe a single-phase BCC/B2 microstructure that is susceptible to solid-state cracking. At low cooling rates (102−104 K/s), FCC phase precipitates out from the BCC/B2 matrix, resulting in enhanced ductility (~10 %) and resistance to solid-state cracking. Site-specific residual stress/strain analysis reveals that the ductile FCC phase can largely accommodate residual stresses, a feature which helps relieve residual strains within the BCC/B2 phase to prevent cracking. Our work underscores the value of exploiting the toolbox of phase transformation pathway engineering for material design during additive manufacturing.more » « less
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Feng, Shuai; Guan, Shuai; Zhang, Shengbiao; Mooraj, Shahryar; Luebbe, Matthew; Fan, Xuesong; Beyer, Kevin A.; Li, Tianyi; Liu, Jian; Kong, Jian; et al (, Additive Manufacturing)
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Zhang, Shengbiao; Hou, Peijun; Mooraj, Shahryar; Chen, Wen (, Surface and Coatings Technology)
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Additive Manufacturing of High-Entropy Alloys: Microstructural Metastability and Mechanical BehaviorGuan, Shuai; Ren, Jie; Mooraj, Shahryar; Liu, Yanfang; Feng, Shuai; Zhang, Shengbiao; Liu, Jian; Fan, Xuesong; Liaw, Peter K.; Chen, Wen (, Journal of Phase Equilibria and Diffusion)
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