Process Optimization, Microstructure and Mechanical Properties of FeCrNi Medium Entropy Alloy Fabricated by Additive Manufacturing

WANG Shuoran; XIANG Chao; GUI Xinyuan; ZHANG Tao; SUN Guifang; HAN Enhou

doi:10.3969/j.issn.1674-6457.2025.08.013

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (8) : 115-126. DOI: 10.3969/j.issn.1674-6457.2025.08.013

High-Entropy Alloy and Amorphous Alloy Forming

Process Optimization, Microstructure and Mechanical Properties of FeCrNi Medium Entropy Alloy Fabricated by Additive Manufacturing

WANG Shuoran^1,2, XIANG Chao^2,*, GUI Xinyuan^1,2, ZHANG Tao², SUN Guifang^2,3, HAN Enhou^2,4

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Abstract

The work aims to fabricate the FeCrNi medium entropy alloy with a high relative density through optimized laser powder bed fusion (LPBF) parameters, to avoid defects affecting the service performance and provide reference for the process development of FeCrNi medium entropy alloy. With FeCrNi MEA powder as the raw material, the process parameter tables were designed to prepare samples, and the volumetric energy density was introduced as a reference index to study the effect of process parameters on the relative density, and the microstructure and mechanical properties of the samples under the optimal process parameters were analyzed. An LPBF FeCrNi MEA with a relative density of 99.96% was successfully fabricated under the following process parameters: laser power of 220 W, scanning speed of 950 mm/s, hatching space of 0.09 mm, layer thickness of 30 μm, and volumetric energy density of 85.77 J/mm³. LPBF FeCrNi MEA exhibited a single FCC phase, with distinct molten tracks and pools perpendicular and parallel to the build direction, averaging grain sizes of 16.83 μm and 18.01 μm, respectively. A high density of geometrically necessary dislocations (GNDs) was observed at grain boundaries, residual stress was primarily concentrated at the edges of molten tracks and pools and elemental distribution was uniform. LPBF FeCrNi MEA demonstrated a yield strength of 597 MPa, tensile strength of 705 MPa, and 27.6% elongation, with ductile fracture behavior. Suboptimal volumetric energy densities will cause incomplete or excessive melting, destabilizing molten pools and reducing densification. Controlling the volumetric energy density moderately is the direction of process optimization. Rapid cooling leads to non-equilibrium solidification, refining grains, forming cellular/columnar structures, and generating residual stresses at edges of molten pools and tracks. The synergy of heterogeneous structures and residual stresses enhances mechanical properties of FeCrNi MEA.

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additive manufacturing / laser powder bed fusion / medium entropy alloy / process optimization / microstructure / mechanical properties

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WANG Shuoran, XIANG Chao, GUI Xinyuan, ZHANG Tao, SUN Guifang, HAN Enhou. Process Optimization, Microstructure and Mechanical Properties of FeCrNi Medium Entropy Alloy Fabricated by Additive Manufacturing[J]. Journal of Netshape Forming Engineering. 2025, 17(8): 115-126 https://doi.org/10.3969/j.issn.1674-6457.2025.08.013

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