High entropy alloys (HEA) have been one of the most attractive groups of materials for researchers in the last several years. Since HEAs are potential candidates for many (e.g., refractory, cryogenic, medical) applications, their properties are studied intensively. The most frequent method of HEA synthesis is arc or induction melting. Powder metallurgy is a perspective technique of alloy synthesis and therefore in this work the possibilities of synthesis of HfNbTaTiZr HEA from powders were studied. Blended elemental powders were sintered, hot isostatically pressed, and subsequently swaged using a special technique of swaging where the sample is enveloped by a titanium alloy. This method does not result in a full density alloy due to cracking during swaging. Spark plasma sintering (SPS) of mechanically alloyed powders resulted in a fully dense but brittle specimen. The most promising result was obtained by SPS treatment of gas atomized powder with low oxygen content. The microstructure of HfNbTaTiZr specimen prepared this way can be refined by high pressure torsion deformation resulting in a high hardness of 410 HV10 and very fine microstructure with grain size well below 500 nm.

In the present work, a series of high-entropy alloys based on refractory metals Hf, Nb, Ta, Ti, V, and Zr with various compositions have been systematically investigated. Our study revealed that a bcc single-phase solid solution of a Hf-Nb-Ta-Ti-V-Zr system is thermodynamically stable only at high temperatures above 1000 °C. At lower temperatures, the phase separation into disordered bcc phases with slightly different chemical compositions occurs. Despite the phase separation, a single-phase random solid solution can be saved at room temperature as a metastable phase by rapid cooling of the sample from high temperature. The microstructure of a single-phase metastable random solid solution was characterized and compared with the microstructure of the as-cast state. Furthermore, the mechanical properties of annealed and as-cast alloys were compared. Interestingly, both states exhibit comparable mechanical properties. It indicates that from the point of view of practical applications, a mechanical mixture of disordered bcc solutions is as good as single-phase random solid solution.