The aerospace industry is constantly seeking new advanced materials with high-temperature properties. Since turbine engines are subject to arduous operating conditions, the alloys used for this application are required to exhibit high fatigue, creep, oxidation, and corrosion resistances. The emerging high-entropy alloys (HEAs) show a positive potential for replacing nickel superalloys in turbine components. High-entropy alloys are composed of five or more principal elements that generate simple crystal structures-mostly BCC and FCC – that are stable at elevated temperatures. High entropy alloy fabrication typically employs traditional methods, which impose strong limitations on geometric freedom and microstructure control. Additive manufacturing represents a promising alternative since it allows for some of the drawbacks associated with subtractive technologies. In this research, AlCoCr2FeMo0.5Ni high entropy alloy was processed using Laser Direct Energy Deposition technology with the aim of achieving a homogeneous deposition, free of defects and well adherent to the substrate. Single-track and multi-track tests were carried out with different combinations of laser power, scanning speed and powder feed rate. A preliminary evaluation of the results using the optical microscope revealed a correlation between the defects and the process parameters, enabling the identification of the optimal print setup. An in-depth analysis under a scanning electron microscope was performed to assess the microstructure and distribution of alloying elements. Additionally, microhardness tests were carried out to confirm the uniformity of phases within the deposition. Finally, the topography of the layer was assessed and correlated to process parameters in view of a future multi-layer approach.
Keywords
- Coating
- Direct Energy Deposition
- High Entropy Alloys
- Laser Powder Deposition