This work presents two new compositions of high entropy alloys (HEAs) that were designed with the aim of obtaining a body-centered cubic (BCC) phase with high hardness values and a moderate density. Sintering was performed using Spark Plasma Sintering (SPS) with different heating rates to determine the influence of the processing parameters on the phase formation. The microstructural study revealed that the presence of Ni in the composition promoted phase separation, and the mechanical study confirmed a clear influence on the mechanical properties of both the composition and heating rate. The combination of microscopy with compression and nanoindentation tests at room and high temperature made it possible to advance our understanding of the relationships between the composition, processing, and properties of this emerging group of alloys.

One of the attractive characteristics of high entropy alloys (HEAs) is the ability to tailor their composition to obtain specific microstructures and properties by adjusting the stoichiometry to obtain a body-centered cubic (BCC) or face-centered cubic (FCC) structure. Thus, in this work, the target composition of an alloy of the FeCrCoNi family has been modified by adjusting the Al/Cu ratio in order to obtain a BCC crystalline structure. However, processing conditions always play a key role in the final microstructure and, therefore, in this work, the microstructure evolution of FeCrCoNiAl_1.8Cu_0.5 HEA sintered by different powder metallurgy (PM) techniques has been investigated. The techniques used range from the conventional PM sintering route, that uses high heating rates and sintering times, going through a fast sintering technique such as spark plasma sintering (SPS) to the novel and promising ultrafast sintering technique electrical resistance sintering (ERS). Results show that the increase in the processing time favours the separation of phases and the segregation of elements, which is reflected in a substantial change in the hardness of the alloy. In conclusion, the ERS technique is presented as a very promising consolidation technique for HEA.

The structure of FeCoNiCrAl1.8Cu0.5 high-entropy alloys (HEA) obtained by two different routes has been studied. The selection of the composition has followed the Hume–Rothery approach in terms of number of itinerant electrons (e/a) and average atomic radius to control the formation of specific phases. The alloys were obtained either from a mixture of elemental powders or from gas-atomised powders, being consolidated in both cases by uniaxial pressing and vacuum sintering at temperatures of 1200 °C and 1300 °C. The characterization performed in the sintered samples from both types of powder includes scanning electron microscopy, X-ray diffraction, differential thermal analysis, and density measurements. It was found that the powder production techniques give similar phases content. However, the sintering at 1300 °C destroys the achieved phase stability of the samples. The phases identified by all techniques and confirmed by Thermo-Calc calculations are the following: a major Co-Ni-Al-rich (P1) BCC phase, which stays stable after 1300 °C sintering and homogenising TT treatments; a complex Cr-Fe-rich (P2) B2 type phase, which transforms into a sigma phase after the 1300 °C sintering and homogenising TT treatments; and a very minor Al-Cu-rich (P3) FCC phase, which also transforms into Domain II and Domain III phases during the heating at 1300 °C and homogenising TT treatments.

Multi-principal element alloys are considered a promising option for high-temperature applications due to their potential for excellent oxidation resistance. However, processing conditions play a crucial role in determining the final microstructure and, consequently, the material's properties. This study examines the impact of the microstructure on the mechanical properties and high-temperature oxidation behavior of a non-equiatomic AlCrCoFeNi _2.1 eutectic multi-principal element alloy. The alloy was fabricated using traditional arc melting and a powder metallurgy (PM) technique, specifically, spark plasma sintering (SPS). While the fabrication method had a minimal effect on the primary phases present, it significantly impacted the microstructure morphology. All the samples consisted primarily of a mixture of body-centered cubic and face-centered cubic phases. However, the arc-melted alloy exhibited a typical lamellar structure, whereas the SPS samples displayed globular structures in certain regions. Using a PM method significantly refined the grain size. PM routes enabled the microstructure of the samples to be tailored to improve mechanical properties and oxidation resistance. During oxidation tests, the samples fabricated using PM exhibited more homogeneous oxide layers.