Microstructural and mechanical characterisation of cantor type high entropy alloy produced by wire arc additive manufacturing

Journal article, 2026

This study investigates the microstructural and mechanical properties of a Cantor type high entropy alloy (CoCrFeMnNi) produced via wire arc additive manufacturing (WAAM). Utilizing metal powder cored wire (MPCW), this research aims to address the challenges of producing high entropy alloys (HEAs) using cost-effective and scalable manufacturing methods. The CoCrFeMnNi alloy was deposited on a stainless steel substrate, forming a thin-walled structure. Comprehensive microstructural analysis, including optical microscopy, scanning electron microscopy (SEM), and transmission electron microscopy (TEM), revealed a homogeneous distribution of elements with minor Mn segregation and identified non-metallic inclusions such as MnS and oxides. The alloy exhibited elongated columnar grains with dendritic structures due to the high thermal gradients during deposition. Mechanical testing showed yield strengths ranging from 200 to 300 MPa and ultimate tensile strengths between 450 and 500 MPa, with elongation to fracture varying from 25 to 58%, depending on the position within the built structure. The hardness ranged from 110 to 176 HV10, with increased values at the edges and bottom due to faster cooling rates and the presence of Cr-rich precipitates. This study demonstrates that WAAM is a viable method for producing high-quality HEAs with competitive mechanical properties, promoting its potential for industrial applications.