A precipitation hardening high-entropy alloy (HEA) (FeCoNi)₈₆Al₇Ti₇ was fabricated by selective laser melting (SLM) and ageing treated under different temperatures and time conditions. Yield strength of the aged HEA increases substantially from 710 to 934 and then to 1203 MPa. Theoretical analyses reveal that the coherent L1₂ precipitate contributes most of the improved strength for the aged HEAs, whereas recovery during ageing causes the decrease of dislocation density thus exerts a softening effect. In addition, it is found that ductility decreases with increasing volume fraction of the incoherent L2₁ precipitates. Based on a void growth model, the trend is qualitatively explained. Moreover, a new fracture mode, intercellular fracture, is proposed to account for the strong dependence of fracture dimple size on the dislocation cells, also directly validated by delicate microstructural examination. The findings provide an effective strengthening method and propose a unique fracture mechanism for the additively manufactured HEA.

Strength and ductility were simultaneously enhanced in the additively manufactured CoCrFeMnNi high-entropy alloy by laser powder bed fusion (LBPF) under reactive N₂ atmosphere. It was found that nitrogen atoms picked up during additive manufacturing line-up to form ordered nitrogen complexes (ONCs) in the octahedral interstitial position of the HEA matrix. Dislocation multiplication is then facilitated by the formation of ONCs during LPBF, leading to a higher dislocation density with smaller dislocation cells. Dislocation strengthening, combined with interstitial strengthening, endows the additively manufactured HEA with the yielding strength of 690 MPa, 15% higher than that of the counterparts fabricated under inert atmosphere. More interestingly, the ONCs stimulate dislocation nucleation and engender more heterogeneous microstructure, giving rise to an outstanding ductility of 15.3%, with an increment of 34%. As a result, the strength–ductility trade-off was successfully reversed by the nitrogen doping during LPBF under reactive atmosphere.

Forming complex geometries using the casting process is a big challenge for bulk metallic glasses (BMGs), because of a lack of time of the window for shaping under the required high cooling rate. In this work, we open an approach named the “entire process vacuum high pressure die casting” (EPV-HPDC), which delivers the ability to fill die with molten metal in milliseconds, and create solidification under high pressure. Based on this process, various Zr-based BMGs were prepared by using industrial grade raw material. The results indicate that the EPV-HPDC process is feasible to produce a glassy structure for most Zr-based BMGs, with a size of 3 mm × 10 mm and with a high strength. In addition, it has been found that EPV-HPDC process allows complex industrial BMG parts, some of which are hard to be formed by any other metal processes, to be net shaped precisely. The BMG components prepared by the EVP-HPDC process possess the advantages of dimensional accuracy, efficiency, and cost compared with the ones formed by other methods. The EVP-HPDC process paves the way for the large-scale application of BMGs.

Recently, high-entropy alloy thin films (HEATFs) with nanocrystalline structures and high hardness were developed by magnetron sputtering technique and have exciting potential to make small structure devices and precision instruments with sizes ranging from nanometers to micrometers. However, the strength and deformation mechanisms are still unclear. In this work, nanocrystalline Al_0.3CoCrFeNi HEATFs with a thickness of ~4 μm were prepared. The microstructures of the thin films were comprehensively characterized, and the mechanical properties were systematically studied. It was found that the thin film was smooth, with a roughness of less than 5 nm. The chemical composition of the high entropy alloy thin film was homogeneous with a main single face-centered cubic (FCC) structure. Furthermore, it was observed that the hardness and the yield strength of the high-entropy alloy thin film was about three times that of the bulk samples, and the plastic deformation was inhomogeneous. Our results could provide an in-depth understanding of the mechanics and deformation mechanism for future design of nanocrystalline HEATFs with desired properties.