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By adjusting the parameters in the additive manufacturing process, the optimization of the microstructure and mechanical properties of 2205 duplex stainless steel (DSS) is of great significance to ensure the reliability of the material in harsh environments. The 2205 DSS samples are prepared by cold metal transfer conditions of interlayer cooling time of 0, 30, 60, and 120 s, respectively, and the microstructure and properties of the samples are characterized in detail. With the increase of cooling time, the height of the samples increases, and the width decreases, and no defects are found in all the samples. It also reduces the grain size and contributes to the uniform distribution of grains. With the extension of cooling time, the proportion of austenitic phase gradually increases from 41.60% to 47.36%, while the proportion of ferrite decreases correspondingly. The mechanical properties of the samples are tested. With the increase of cooling time, the hardness of the samples increases from 646.32(±1.46) to 679.36(±7.27) MPa, and the ductility decreases from 60.10(±0.50)% to 43.67(±2.10)%. The results show that the interlayer cooling time can be used to regulate the formation, microstructure, and properties of DSS. [ABSTRACT FROM AUTHOR]

Iron-rich medium-entropy alloys (MEAs) have attracted attention due to the balance for cost and properties of alloy. In this study, a combined metastability engineering and eutectic high-entropy alloys (EHEAs) design strategy were employed to develop a cost-effective, iron-rich MEAs for the Fe–Cr–Ni–Al MEAs system using CALPHAD simulations. This approach enabled the tailored control of soft and hard phases within the non-isoatomic MEAs system by manipulating the elemental ratios. Specifically, increasing the aluminum (Al) content promoted the stability of the BCC/B2 phase, and the microstructure of the MEA transitioned from a single-phase FCC structure to a mixed FCC + BCC/B2 structure, culminating in a final single-phase BCC/B2 structure. This BCC/B2 phase precipitation strengthening mechanism led to enhanced microhardness and yield strength in MEAs with high Al content. Notably, the Al 11 -as alloy demonstrated a yield strength of 692.7 ± 30.4 MPa (precipitation strengthening is ∼428.98 MPa, accounting for the true yield strength of the alloy ∼61.9 %), with an ultimate tensile strength reaching a maximum value of 992.3 ± 32.77 MPa. Moreover, the alloy retained a satisfactory elongation of 7.1 ± 2.9 %. These efforts hold promise for the development and application of cost-effective, iron-rich MEAs for the Fe–Cr–Ni–Al MEAs system. • A cost-effective, iron-rich MEAs for the Fe–Cr–Ni–Al MEAs system using CALPHAD simulations. • Thermo-dynamic phase calculation proves to be a valuable tool for MEAs design and phase prediction. • The tailored control of soft and hard phases within the non-isoatomic MEAs system by manipulating the elemental ratios. • Precipitation strengthening plays a significant role in enhancing the overall strength of the Fe 57.88 (CrNi) (42.12- x) Al x MEAs. [ABSTRACT FROM AUTHOR]

Wire arc additive manufacturing (WAAM) has emerged as a promising method for additive manufacturing due to its high efficiency and cost-effectiveness. This study aimed to fabricate Co-based Elgiloy by WAAM based on cold metal transfer technology. An 18-layers thin alloy wall was prepared. The microstructure, texture and mechanical properties of the as-deposited samples were investigated. Results indicated that the prepared alloy had good formability and was composed of a single face center cubic structure. The tensile properties of the alloy exhibited anisotropy due to the large number of columnar grains growing along the building direction in the alloy. The tensile samples along the building direction exhibited lower yield strength but better elongation due to the columnar grain growth direction and the softening effect of the remelted zone. [ABSTRACT FROM AUTHOR]

With low-cost and high-efficiency advantages, wire arc additive manufacturing (WAAM) has become a promising method for preparing high-entropy alloys (HEAs). This study prepared CoCrFeNiMo 0.2 HEA samples using cold metal transfer technology. By changing the deposition parameters, different heat inputs were realized. The forming quality, microstructure, and mechanical properties of the as-deposited CoCrFeNiMo 0.2 HEA samples with different heat inputs were explored by macroscopic observation, optical microscopy, X-ray diffraction, scanning electron microscopy, energy-dispersive spectroscopy, electron backscatter diffraction, microhardness and tensile test at room temperature. Results show that the alloy prepared by WAAM had a typical columnar crystal composition in deposition direction and a strong {100}〈001〉 cubic texture. With the increased heat input, the forming of the sample worsened, and an obvious step effect appeared, increasing the fine grain region between the sample layers. Due to the heat accumulation and poor heat dissipation, the phase with less Mo grew, deteriorating its mechanical properties. The growth direction of columnar crystals in the sample was consistent with the vertical tensile direction, improving the sample's tensile properties perpendicular to the deposition direction. • Wire arc additive manufacturing (WAAM) of CoCrFeNiMo 0.2 high-entropy alloys. • WAAM can produce high-entropy alloys with lower cost and high efficiency. • The effects of heat input on the forming quality of HEAs was investigated. • The microstructure and mechanical properties of the CoCrFeNiMo 0.2 HEAs were investigated. [ABSTRACT FROM AUTHOR]

Wire and arc additive manufacturing (WAAM) is a promising technology for the preparation of refractory metal functional gradient materials (FGMs) due to its high material utilization, high deposition efficiency and ability to create large-sized parts. In the present work, 316L/IN625 FGM with chemical composition gradients of 25 wt% and 100 wt% were fabricated using dual-wire plasma arc additive manufacturing (DW-PAAM) by changing the wire feeding speeds (WFSs) layer by layer. The phase evolution, microstructure, chemical composition and mechanical properties of the FGM were analyzed. The results demonstrated that the microstructure in all regions was predominantly the austenite phase, and no cracks or defects were observed. The microstructure of the 100 wt% 316L zone was composed of the austenite phase (face-centered cubic, FCC) and a small amount of ferrite phase (body-centered cubic, BCC), whereas mainly FCC structure was observed in the other chemical composition regions. There was a certain error between the actual composition gradient and the designed gradient. The microhardness transition of S1 was smoother and wider, while the tensile test results of S2 were better. In addition, the position of the tensile fracture was different for S1 and S2. In conclusion, the DW-PAAM process shows great potential for manufacturing FGM with desirable properties for various industrial applications. Further studies are warranted to optimize process parameters and develop new design strategies to enhance the performance of FGM in various industrial applications. • 316L/IN625 FGM with composition gradients of 25 wt% and 100 wt% were prepared by the DW-PAAM process. • The microstructure in all regions was predominantly the FCC structure, no cracks or defects were observed. • A certain error existed between the chemical composition curve of the actual gradient and the design gradient. • Sample S1 has the lowest microhardness and tensile strength in the zone of 75 wt% 316L. [ABSTRACT FROM AUTHOR]

Powder plasma arc additive manufacturing (PPA-AM) is a promising method for the preparation of high-entropy alloys (HEAs), and has the advantages of low cost, high efficiency, and high quality. In this study, the CoCrFeNiW x (x = 0, 0.2, 0.5, 0.7, and 1.0) HEAs were successfully prepared via the PPA-AM technique. Microstructure and mechanical properties of alloys with different W content were investigated. The results showed that the microstructure changed from a single FCC phase (x = 0) to the dual-phase FCC + µ (x = 0.2 and 0.5), and then to a three-phase combination of FCC + µ + BCC (x = 0.7 and 1.0) with the addition of W. The volume fraction of the µ phase and BCC phase increases with the increase in W content, while the size of FCC columnar grain is significantly reduced. The solid-solution strengthening of the FCC phase and the second phase strengthening were mainly responsible for the increase in the microhardness (136–413 HV) and yield strength (187–567 MPa) while the brittleness of the μ phase contributes to the expansion of the crack, which leads to a decrease in the ductility (50.8% to 0.3%). These results can provide a systematic understanding of the phase transformation of PPA-AM HEAs with different W content and its effects on the mechanical properties. • Powder plasma arc additive manufacturing (PPA-AM) of CoCrFeNiWx high-entropy alloys. • PPA-AM can produce high-entropy alloys with lower cost and high efficiency. • The microstructure and mechanical properties of the CoCrFeNiWx HEAs were investigated. • W element can promote the phase transformation from FCC phase to µ and BCC phase. • The strength of the HEAs was significantly improved with addition of W. [ABSTRACT FROM AUTHOR]

Powder plasma arc additive manufacturing (PPA-AM) is a promising method for fabricating high-entropy alloys (HEAs). However, the characteristics of thermal cycling during the PPA-AM process and the mechanism of subsequent heat treatment on the microstructure and mechanical properties are unclear. In this study, an Al 1.2 CoCrFeNi 2.1 HEA with dual-phase (FCC + B2) was fabricated via PPA-AM. The microstructure and mechanical properties of the as-built and heat-treated samples were explored. The crystallographic orientations of the FCC and B2 phases were also determined. Because the alloy in the bottom region was affected by thermal cycling, B2 particles precipitated in the FCC phase, and FCC particles precipitated in the B2 phase. During the tensile test, the phase boundary between B2 matrix and FCC particles produced cracks preferentially. These cracks reduced the strength and elongation of the alloy. After heat treatment at 1200 °C, the FCC and B2 precipitates formed globular shapes inside the B2 and FCC grain matrix, respectively. The alloy showed a uniform structure and the ductility of the alloy was improved significantly. This work elucidates the mechanisms of thermal cycling and heat treatment on the microstructure and mechanical properties of the alloy. [ABSTRACT FROM AUTHOR]

• AlCoCrFeNi 2.1 high-entropy alloy was fabricated by PPA-AM method. • The B2 phase precipitates at the bottom region of the HEA due to thermal cycling. • The ductility of the HEA increases and the strength decreases due to thermal cycling. High-entropy alloys (HEAs) are a novel class of materials. In this study, the AlCoCrFeNi 2.1 HEA was prepared using powder plasma arc additive manufacturing (PPA-AM). The influence of thermal cycling in the PPA-AM process on AlCoCrFeNi 2.1 HEA was investigated. The AlNi elements in the FCC phase in the bottom region were aggregated by thermal cycling to form the acicular B2 particles. This weakened the solid solution strengthening effect of the FCC phase, reduced its yield strength (421 to 389 MPa), and improved its ultimate tensile strength (929 to 981 MPa) and elongation (15.6 % to 21.0 %). The results of this study might have reference significance for the AlCoCrFeNi alloy system. [ABSTRACT FROM AUTHOR]

High-entropy alloys (HEAs) are promising coating materials for wear resistance applications. However, the preparation of HEA coatings with powder has the disadvantages of high cost and low efficiency. In this study, an innovative triple-wire plasma arc cladding (TW-PAC) method was used to prepare HEA coatings. Nonequiatomic Cr-Fe-Ni-Ti x (x is Ti wire feeding speed, x = 0, 0.5, 0.8 and 1.0 m/min, denoted as Ti 0 , Ti 0.5 , Ti 0.8 and Ti 1.0) HEA coatings were successfully prepared by using three commercial wires (ERTi-2, ER304L and Cr 20 Ni 80 wire). With increasing Ti content, the structure of the Cr-Fe-Ni-Ti x HEA coatings changed from the single FCC phase to the FCC + γ′ (Ni 3 Ti) + Laves (Fe 2 Ti) phase, and the microhardness of the coatings increased from 137 HV to 873 HV. Due to the addition of Ti, Ni 3 Ti and Fe 2 Ti phases with high hardness precipitated in the alloy coating, accompanied by the solid solution strengthening effect of the FCC phase, the wear resistance of the coatings was significantly improved (from 9.67 × 10−4 to 1.49 × 10−4 mm3/N·m). The results of this study contribute to the preparation of thick HEA coatings overlarge areas at low cost and with high efficiency and provide new insights into Cr-Fe-Ni-Ti x HEA coatings. • Triple-wire plasma arc cladding (TW-PAC) of Cr-Fe-Ni-Tix high-entropy alloy coatings. • High-entropy alloy coatings were prepared using three commercial wires. • The phase of the coatings changed from FCC to FCC + Ni 3 Ti + Fe 2 Ti with the addition of Ti. • The wear resistance of the coatings was significantly improved with addition of Ti. [ABSTRACT FROM AUTHOR]