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Harnessing metastability for grain size control in multiprincipal element alloys during additive manufacturing

Author

Listed:
  • Akane Wakai

    (Cornell University)

  • Jenniffer Bustillos

    (Cornell University)

  • Noah Sargent

    (University of Pittsburgh)

  • Jamesa L. Stokes

    (NASA Glenn Research Center)

  • Wei Xiong

    (University of Pittsburgh)

  • Timothy M. Smith

    (NASA Glenn Research Center)

  • Atieh Moridi

    (Cornell University)

Abstract

Controlling microstructure in fusion-based metal additive manufacturing (AM) remains a significant challenge due to the many parameters that directly impact solidification condition. Multiprincipal element alloys (MPEAs), also known as high entropy alloys, offer a vast compositional space to design for microstructural engineering due to their chemical complexity and exceptional properties. Here, we use the FeMnCoCr system as a model platform for exploring alloy design in MPEAs for AM. By exploiting the decreasing stability of the face-centered cubic phase with increasing Mn content, we achieve notable grain refinement and breakdown of epitaxial columnar grain growth. We employ a multifaceted approach encompassing thermodynamic modeling, operando synchrotron X-ray diffraction, multiscale microstructural characterization, and mechanical testing to gain insight into the solidification physics and its ramifications on the resulting microstructure of FeMnCoCr MPEAs. This work aims toward tailoring desirable grain sizes and morphology through targeted manipulation of phase stability, thereby advancing microstructure control in AM applications.

Suggested Citation

  • Akane Wakai & Jenniffer Bustillos & Noah Sargent & Jamesa L. Stokes & Wei Xiong & Timothy M. Smith & Atieh Moridi, 2025. "Harnessing metastability for grain size control in multiprincipal element alloys during additive manufacturing," Nature Communications, Nature, vol. 16(1), pages 1-10, December.
    • Handle: RePEc:nat:natcom:v:16:y:2025:i:1:d:10.1038_s41467-025-56616-0
    DOI: 10.1038/s41467-025-56616-0
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    References listed on IDEAS

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    1. Zhiming Li & Konda Gokuldoss Pradeep & Yun Deng & Dierk Raabe & Cemal Cem Tasan, 2016. "Metastable high-entropy dual-phase alloys overcome the strength–ductility trade-off," Nature, Nature, vol. 534(7606), pages 227-230, June.
    2. John H. Martin & Brennan D. Yahata & Jacob M. Hundley & Justin A. Mayer & Tobias A. Schaedler & Tresa M. Pollock, 2017. "3D printing of high-strength aluminium alloys," Nature, Nature, vol. 549(7672), pages 365-369, September.
    3. Jie Ren & Yin Zhang & Dexin Zhao & Yan Chen & Shuai Guan & Yanfang Liu & Liang Liu & Siyuan Peng & Fanyue Kong & Jonathan D. Poplawsky & Guanhui Gao & Thomas Voisin & Ke An & Y. Morris Wang & Kelvin Y, 2022. "Strong yet ductile nanolamellar high-entropy alloys by additive manufacturing," Nature, Nature, vol. 608(7921), pages 62-68, August.
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