In this paper, a laser-based directed energy deposition (DED) technique is used to fabricate FeCoNiCr and CrMnFeCoNi multi-principal-element alloys (MPEAs). Comparing the above samples, the FeCoNiCr samples with coarse columnar grains cracked, while the CrMnFeCoNi samples with equiaxed grain were crack-free. The strategy that removes cracks is to induce a columnar-grain-to-equiaxed-grain transition (CET) with Mn addition to offer more grain boundaries to withstand residual stress in the process of DED-fabricated FeCoNiCr and to help minimize hot cracking. Furthermore, the yield strength, tensile strength, and tensile ductility of the DED-fabricated CrMnFeCoNi obviously improved compared with the DED-fabricated CoCrFeNi and exhibited better isotropic mechanical properties. The present work provides a novel strategy to utilize CET for resisting crack propagation in the process DED-fabricated MPEAs and improvement in mechanical properties of MPEAs.

Titanium for additive manufacturing presents a challenge in the control of costs in the fabrication of products with expanding applications compared with cast titanium. In this study, hydrogenated–dehydrogenated (HDH) titanium powder with a low cost was employed to produce spherical Ti powder using the radiofrequency plasma (RF) technique. The spherical Ti powder was used as the raw material for laser directed energy deposition (LDED) to produce commercially pure titanium (CP-Ti). Microstructural analyses of the powder revealed that RF treatment, not only optimized the shape of the titanium powder, but also benefited in the removal of the residual hydride phase of the powder. Furthermore, the LDED-HDH-RF-produced samples showed an excellent combination of tensile strength and tensile ductility compared to the cast and the LDED-HDH-produced samples. Such an enhancement in the mechanical properties was attributed to the refinement of the α grain size and the dense microstructure. The present work provides an approach for LDED-produced CP-Ti to address the economic and mechanical properties of the materials, while also providing insights into the expanding application of HDH titanium powder.