Research Status and Prospects of Additive Manufacturing of High-entropy Alloys

LI Xiaojun; SONG Changhong; PAN Mengyang

doi:10.3969/j.issn.1674-6457.2026.07.011

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (7) : 116-131. DOI: 10.3969/j.issn.1674-6457.2026.07.011

Additive Manufacturing

Research Status and Prospects of Additive Manufacturing of High-entropy Alloys

LI Xiaojun^1,*, SONG Changhong², PAN Mengyang³

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Abstract

High-entropy alloys have become a leading research direction in structural materials due to their high mixing entropy effect, solid solution stability, and excellent comprehensive properties. Additive manufacturing provides a new technological platform for the composition design, microstructure regulation, and performance improvement of high-entropy alloys by offering rapid solidification, high structural complexity forming capabilities, and controllable process windows. The work aims to review the research progress in additive manufacturing of high-entropy alloys, systematically summarize the main additive manufacturing processes, typical material systems, microstructure evolution laws, physical and mechanical performance manifestations, and related process optimization strategies and focus on expounding the key roles of rapid solidification, melt pool dynamics, and multi-level thermal cycling in the formation of microstructure. Furthermore, the mechanical properties, corrosion resistance, wear resistance, and high-temperature service behavior of different high-entropy alloy systems are combined to summarize the current main methods for performance improvement, including process parameter control, alloy composition optimization, and various post-treatment methods. Although additive manufacturing significantly expands the design and application potential of high-entropy alloys, it still faces several challenges: compositional segregation, pores and hot cracks induced by rapid solidification can hardly be completely eliminated; multiple passes and multi-layer thermal cycles lead to pronounced microstructural anisotropy and fluctuating mechanical properties; powder oxidation, elemental volatilization and insufficient phase stability degrade service reliability; and the lack of a clear processing-microstructure-performance correlation model limits the predictable design of materials. Based on this, the work looks forward to future development directions, including multi-physical field simulation-driven microstructure prediction, machine learning-assisted process optimization, the development of new high-entropy powder systems, in-situ reaction additive manufacturing, and the construction of multi-material/gradient structures. With the maturity of high-throughput additive manufacturing technology and the establishment of a standardized system, additive manufacturing of high-entropy alloys is expected to achieve more widespread and reliable engineering applications in aerospace, energy equipment, and extreme service environments.

Key words

high-entropy alloys / additive manufacturing / microstructure evolution / melt pool dynamics / performance optimization

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LI Xiaojun, SONG Changhong, PAN Mengyang. Research Status and Prospects of Additive Manufacturing of High-entropy Alloys[J]. Journal of Netshape Forming Engineering. 2026, 18(7): 116-131 https://doi.org/10.3969/j.issn.1674-6457.2026.07.011

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Funding

Research Project of Henan’s Scientific and Technological Think Tank (HNKJ ZK-2025-38B); Zhengzhou City 2026 Social Science Research Topic (ZSLX2026-625); General Project for Humanities and Social Sciences Research in Institutions of Higher Learning under the Education Department of Henan Province (2027-ZDJH-872)