As an attractive high-entropy alloy, AlCrCoNiCu high-entropy alloy has excellent corrosion resistance, wear resistance, and anti-bacterial capabilities, and is considered to be a potential substitute material for marine and nuclear industry materials with great potential. One key to further optimizing the performance of high entropy alloy was to prepare high entropy alloy powder materials with uniform composition, good flow-ability, and stable performance. In this work, the AlCrCoNiCu high entropy alloy powder was prepared by the gas atomization method. The results indicated that the powder was spherical in shape, homogeneous in composition, and composed of a face-center cubic (FCC) phase. After adding Fe and Mn elements, FCC and body-center cubic (BCC) phases appeared and the particle size of the powder was mainly located at 10–50 μm. Furthermore, the larger the particle size was, the more obvious the surface roughness was. With the decreasing powder size, its shape became relatively regular, and the surface roughness decreased. This work provided an experimental and theoretical reference for preparing high-performance single-phase and multi-phase high entropy alloy spherical powders.

The FeCoNiCrAl_0.1 high entropy alloys (HEAs) and pure copper (Cu) composite plates were successfully fabricated by the explosive welding technique using two different gap distances. The interfacial microstructure, elemental distribution, grain structure of vortex zone and hardness were characterized using optical microscopy (OM), scanning electron microscopy (SEM), electron backscattered diffraction (EBSD), nanoindentation and micro-hardness tester. The explosive weldability window was calculated to verify the weldability of HEAs and Cu. The results indicated that the Cu/HEA composites presented typical wavy structures without visible defects and have an excellent bonding quality. The elements mixed and formed intermetallic compounds at the vortex zones. The grains near the vortex zones showed strong deformation, and phase transformation occurred. Compared with the matrix metals, the hardness of Cu and HEAs increased near the welding interface and sharply increased to 375 HV near the vortex zone.

Wire arc additive manufacturing (WAAM) technology is widely used in the fields of aerospace, shipbuilding, and automobile industry due to the advantages of fast forming speed, high material utilization and low production cost. WAAM is extremely sensitive to parameters, and different processes and materials produce different deposition effects and properties. Therefore, it is of great significance to study the WAAM formability of various materials. Herein, the microstructure, mechanical properties, and galvanic corrosion behavior of the low-carbon high-strength steel (10CrNi3MoV) fabricated by cold metal transfer (CMT) WAAM technology were investigated. The single-channel multilayer deposition parts were prepared by reciprocating deposition, and the forming parts were divided into six zones by observing the different positions of the structure: matrix, heat-affected zone, remelting zone, initial deposition zone, interlayer zone, and interlayer bonding zone. Electron backscattered diffraction (EBSD) analysis showed that the amount of recrystallization and substructure in the deposition layer had no obvious change, and the texture phenomenon was the most obvious in the initial deposition zone of the pole map reaction. The texture phenomenon gradually weakened with the increase of the deposition layers. The microhardness from the matrix to the deposition stable zone was tested. The hardness of the matrix changed smoothly, that of the heat-affected zone was the largest, and that of the deposition layer was 221–282 HV_0.2. The tensile properties were tested in different directions and angles, and the yield strength and tensile strength of the deposited layer were more than 550 MPa and 760 MPa, respectively. The galvanic corrosion behavior between the deposited layer and the matrix was investigated, and the polarization curve showed that the corrosion potential of the deposited layer was lower than that of the matrix, and the corrosion current density of the deposited layer was higher than that of the matrix.

The effect of beam oscillating amplitude on the microstructure and performance of AZ80 Mg alloy cladded with Al-Mg alloy coating by laser–arc hybrid welding was studied. The penetration depth decreases significantly while welds are widened because of the increase in the oscillating area of a laser beam. Alloy segregation and keyhole-induced porosity can be suppressed by the laser beam oscillation. With the increase in the oscillating amplitude, the Al distribution becomes uniform in the weld seam because of the rapid and fierce stirring by the oscillating laser. However, the diluting of the cladded Al alloy restrains the formation of the brittle Mg₁₇Al₁₂ phase, and then causes the weakening of hardness and wear resistance of the cladded layer. Considered comprehensively, the optimized oscillating amplitude was 1 mm, which can produce the weld seam with good appearance, fewer segregation and porosity defects, and acceptable hardness and wear resistance.