IDEAS home Printed from https://ideas.repec.org/a/nat/natcom/v16y2025i1d10.1038_s41467-025-56616-0.html
   My bibliography  Save this article

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
    as

    Download full text from publisher

    File URL: https://www.nature.com/articles/s41467-025-56616-0
    File Function: Abstract
    Download Restriction: no
    File URL: https://libkey.io/10.1038/s41467-025-56616-0?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    References listed on IDEAS

    as
    1. 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.
    2. 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.
    3. 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.
    Full references (including those not matched with items on IDEAS)

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Yannick Naunheim & Christopher A. Schuh, 2024. "Multicomponent alloys designed to sinter," Nature Communications, Nature, vol. 15(1), pages 1-9, December.
    2. Jingqi Zhang & Yingang Liu & Gang Sha & Shenbao Jin & Ziyong Hou & Mohamad Bayat & Nan Yang & Qiyang Tan & Yu Yin & Shiyang Liu & Jesper Henri Hattel & Matthew Dargusch & Xiaoxu Huang & Ming-Xing Zhan, 2022. "Designing against phase and property heterogeneities in additively manufactured titanium alloys," Nature Communications, Nature, vol. 13(1), pages 1-10, December.
    3. Punit Kumar & Sheng Huang & David H. Cook & Kai Chen & Upadrasta Ramamurty & Xipeng Tan & Robert O. Ritchie, 2024. "A strong fracture-resistant high-entropy alloy with nano-bridged honeycomb microstructure intrinsically toughened by 3D-printing," Nature Communications, Nature, vol. 15(1), pages 1-9, December.
    4. Anyu Shang & Benjamin Stegman & Kenyi Choy & Tongjun Niu & Chao Shen & Zhongxia Shang & Xuanyu Sheng & Jack Lopez & Luke Hoppenrath & Bohua Peter Zhang & Haiyan Wang & Pascal Bellon & Xinghang Zhang, 2024. "Additive manufacturing of an ultrastrong, deformable Al alloy with nanoscale intermetallics," Nature Communications, Nature, vol. 15(1), pages 1-12, December.
    5. Tong Li & Tianwei Liu & Shiteng Zhao & Yan Chen & Junhua Luan & Zengbao Jiao & Robert O. Ritchie & Lanhong Dai, 2023. "Ultra-strong tungsten refractory high-entropy alloy via stepwise controllable coherent nanoprecipitations," Nature Communications, Nature, vol. 14(1), pages 1-7, December.
    6. Zongrui Pei & Shiteng Zhao & Martin Detrois & Paul D. Jablonski & Jeffrey A. Hawk & David E. Alman & Mark Asta & Andrew M. Minor & Michael C. Gao, 2023. "Theory-guided design of high-entropy alloys with enhanced strength-ductility synergy," Nature Communications, Nature, vol. 14(1), pages 1-8, December.
    7. Zhang, Jingjing & Wang, Biao & Jin, Junhong & Yang, Shenglin & Li, Guang, 2022. "A review of the microporous layer in proton exchange membrane fuel cells: Materials and structural designs based on water transport mechanism," Renewable and Sustainable Energy Reviews, Elsevier, vol. 156(C).
    8. Benjamin P. MacLeod & Fraser G. L. Parlane & Connor C. Rupnow & Kevan E. Dettelbach & Michael S. Elliott & Thomas D. Morrissey & Ted H. Haley & Oleksii Proskurin & Michael B. Rooney & Nina Taherimakhs, 2022. "A self-driving laboratory advances the Pareto front for material properties," Nature Communications, Nature, vol. 13(1), pages 1-10, December.
    9. Yuze Huang & Tristan G. Fleming & Samuel J. Clark & Sebastian Marussi & Kamel Fezzaa & Jeyan Thiyagalingam & Chu Lun Alex Leung & Peter D. Lee, 2022. "Keyhole fluctuation and pore formation mechanisms during laser powder bed fusion additive manufacturing," Nature Communications, Nature, vol. 13(1), pages 1-11, December.
    10. Chongle Zhang & Xiangyun Bao & Mengyuan Hao & Wei Chen & Dongdong Zhang & Dong Wang & Jinyu Zhang & Gang Liu & Jun Sun, 2022. "Hierarchical nano-martensite-engineered a low-cost ultra-strong and ductile titanium alloy," Nature Communications, Nature, vol. 13(1), pages 1-11, December.
    11. Yinghao Zhou & Weicheng Xiao & Dawei Wang & Xu Tang & Zheling Shen & Weipeng Li & Jun Zhang & Shijun Zhao & Junhua Luan & Zibing An & Rongpei Shi & Ming Yan & Xiaodong. Han & C. T. Liu & Yilu Zhao & T, 2025. "Highly printable, strong, and ductile ordered intermetallic alloy," Nature Communications, Nature, vol. 16(1), pages 1-9, December.
    12. Lile Squires & Ethan Roberts & Amit Bandyopadhyay, 2023. "Radial bimetallic structures via wire arc directed energy deposition-based additive manufacturing," Nature Communications, Nature, vol. 14(1), pages 1-11, December.
    13. Michael G. Taylor & Daniel J. Burrill & Jan Janssen & Enrique R. Batista & Danny Perez & Ping Yang, 2023. "Architector for high-throughput cross-periodic table 3D complex building," Nature Communications, Nature, vol. 14(1), pages 1-11, December.
    14. Zhongji Sun & Yan Ma & Dirk Ponge & Stefan Zaefferer & Eric A. Jägle & Baptiste Gault & Anthony D. Rollett & Dierk Raabe, 2022. "Thermodynamics-guided alloy and process design for additive manufacturing," Nature Communications, Nature, vol. 13(1), pages 1-12, December.
    15. Jing Wang & Ping Jiang & Fuping Yuan & Xiaolei Wu, 2022. "Chemical medium-range order in a medium-entropy alloy," Nature Communications, Nature, vol. 13(1), pages 1-6, December.
    16. Wei Chen & Antoine Hilhorst & Georgios Bokas & Stéphane Gorsse & Pascal J. Jacques & Geoffroy Hautier, 2023. "A map of single-phase high-entropy alloys," Nature Communications, Nature, vol. 14(1), pages 1-10, December.
    17. Ashkenazi, Dana, 2019. "How aluminum changed the world: A metallurgical revolution through technological and cultural perspectives," Technological Forecasting and Social Change, Elsevier, vol. 143(C), pages 101-113.
    18. Ruijian Zhu & Yanting Wang, 2024. "A critical edge number revealed for phase stabilities of two-dimensional ball-stick polygons," Nature Communications, Nature, vol. 15(1), pages 1-12, December.
    19. Yao Tang & Haikuo Wang & Xiaoping Ouyang & Chao Wang & Qishan Huang & Qingkun Zhao & Xiaochun Liu & Qi Zhu & Zhiqiang Hou & Jiakun Wu & Zhicai Zhang & Hao Li & Yikan Yang & Wei Yang & Huajian Gao & Ha, 2024. "Overcoming strength-ductility tradeoff with high pressure thermal treatment," Nature Communications, Nature, vol. 15(1), pages 1-8, December.
    20. Xizheng Wang & Yunhao Zhao & Gang Chen & Xinpeng Zhao & Chuan Liu & Soumya Sridar & Luis Fernando Ladinos Pizano & Shuke Li & Alexandra H. Brozena & Miao Guo & Hanlei Zhang & Yuankang Wang & Wei Xiong, 2022. "Ultrahigh-temperature melt printing of multi-principal element alloys," Nature Communications, Nature, vol. 13(1), pages 1-8, December.

    More about this item

    Statistics

    Access and download statistics

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:nat:natcom:v:16:y:2025:i:1:d:10.1038_s41467-025-56616-0. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Sonal Shukla or Springer Nature Abstracting and Indexing (email available below). General contact details of provider: http://www.nature.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.