Accelerated discovery and testing of Fe–Co–Cr–Ni–Mo ferrous medium-entropy alloys: advanced in-situ alloying via direct energy deposition
Traditional trial-and-error alloy design methods have reached their limitations due to the growing complexity of alloy systems such as high-entropy alloys (HEAs). In-situ alloying through direct energy deposition (DED) using elemental powders has been introduced as a high-throughput synthesis method...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-07-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425014243 |
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| author | Jae Heung Lee Ji Yeong Lee Bon Woo Koo Dae-Kyeom Kim Jungwan Lee Eun Seong Kim Hyojeong Ha Taek-Soo Kim Hyoung Seop Kim |
| author_facet | Jae Heung Lee Ji Yeong Lee Bon Woo Koo Dae-Kyeom Kim Jungwan Lee Eun Seong Kim Hyojeong Ha Taek-Soo Kim Hyoung Seop Kim |
| author_sort | Jae Heung Lee |
| collection | DOAJ |
| description | Traditional trial-and-error alloy design methods have reached their limitations due to the growing complexity of alloy systems such as high-entropy alloys (HEAs). In-situ alloying through direct energy deposition (DED) using elemental powders has been introduced as a high-throughput synthesis method for HEA design. However, large melting point differences can cause unmelted particle issues, limiting its applicability to complex alloy systems such as FeCoCrNiMo ferrous medium-entropy alloys (FeMEAs). In this paper, an advanced in-situ alloying method is proposed to facilitate accelerated alloy discovery and testing (ADAT) for FeCoCrNiMo FeMEA systems by using multiple pre-alloyed powders. Three types of powders - Fe65Co20Mo15 (at%), Fe33.4Cr33.3Ni33.3 (at%), and Fe64Co29Cr7 (at%) - were designed and fabricated, reducing the melting point differences while preserving the ability to synthesize a wide range of compositions. A total of 27 FeCoCrNiMo FeMEA samples with different compositions were successfully fabricated via in-situ alloying. Both the compositional homogeneity and precise adherence to the target composition were achieved, underscoring the excellence of the proposed method. In addition, composition-structure-property linkages were constructed over a wide range of compositions, based on the analysis results of the high-throughput synthesized samples. The #4 (Fe53.9Co16.8Cr11.7Ni11.5Mo6.0) and #7 (Fe52.9Co16.1Cr12.8Ni12.5Mo5.6) samples exhibited the highest hardness levels while maintaining an FCC single-phase structure. These selected compositions were fabricated in bulk samples, and tensile testing of bulk samples revealed that Fe53.9Co16.8Cr11.7Ni11.5Mo6.0 demonstrated superior tensile properties with improved strain hardening behavior, identifying it as optimized composition. This study offers valuable insights to advance the development of novel alloys through high-throughput synthesis methods. |
| format | Article |
| id | doaj-art-0ee4e29dcadf4386839265da38520c02 |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-0ee4e29dcadf4386839265da38520c022025-08-20T03:25:12ZengElsevierJournal of Materials Research and Technology2238-78542025-07-013730831910.1016/j.jmrt.2025.06.001Accelerated discovery and testing of Fe–Co–Cr–Ni–Mo ferrous medium-entropy alloys: advanced in-situ alloying via direct energy depositionJae Heung Lee0Ji Yeong Lee1Bon Woo Koo2Dae-Kyeom Kim3Jungwan Lee4Eun Seong Kim5Hyojeong Ha6Taek-Soo Kim7Hyoung Seop Kim8Department of Materials Science and Engineering, Pohang University of Science and Technology (POSTECH), Pohang, 37673, Republic of KoreaDepartment of Materials Science and Engineering, Pohang University of Science and Technology (POSTECH), Pohang, 37673, Republic of KoreaDepartment of Materials Science and Engineering, Pohang University of Science and Technology (POSTECH), Pohang, 37673, Republic of KoreaKorea National Institute of Rare Metals, Korea Institute of Industrial Technology, Incheon, 21655, Republic of KoreaCenter for Advanced Aerospace Materials, Pohang University of Science and Technology (POSTECH), Pohang, 37673, Republic of KoreaCenter for Advanced Aerospace Materials, Pohang University of Science and Technology (POSTECH), Pohang, 37673, Republic of KoreaDepartment of Materials Science and Engineering, Pohang University of Science and Technology (POSTECH), Pohang, 37673, Republic of KoreaKorea National Institute of Rare Metals, Korea Institute of Industrial Technology, Incheon, 21655, Republic of KoreaDepartment of Materials Science and Engineering, Pohang University of Science and Technology (POSTECH), Pohang, 37673, Republic of Korea; Graduate Institute of Ferrous & Eco Materials Technology, Pohang University of Science and Technology (POSTECH), Pohang, 37673, Republic of Korea; Center for Heterogenic Metal Additive Manufacturing, Pohang University of Science and Technology (POSTECH), Pohang, 37673, Republic of Korea; Advanced Institute for Materials Research (WPI-AIMR), Tohoku University, Sendai, 980-8577, Japan; Corresponding author. Department of Materials Science and Engineering, Pohang University of Science and Technology (POSTECH), Pohang, 37673, Republic of Korea.Traditional trial-and-error alloy design methods have reached their limitations due to the growing complexity of alloy systems such as high-entropy alloys (HEAs). In-situ alloying through direct energy deposition (DED) using elemental powders has been introduced as a high-throughput synthesis method for HEA design. However, large melting point differences can cause unmelted particle issues, limiting its applicability to complex alloy systems such as FeCoCrNiMo ferrous medium-entropy alloys (FeMEAs). In this paper, an advanced in-situ alloying method is proposed to facilitate accelerated alloy discovery and testing (ADAT) for FeCoCrNiMo FeMEA systems by using multiple pre-alloyed powders. Three types of powders - Fe65Co20Mo15 (at%), Fe33.4Cr33.3Ni33.3 (at%), and Fe64Co29Cr7 (at%) - were designed and fabricated, reducing the melting point differences while preserving the ability to synthesize a wide range of compositions. A total of 27 FeCoCrNiMo FeMEA samples with different compositions were successfully fabricated via in-situ alloying. Both the compositional homogeneity and precise adherence to the target composition were achieved, underscoring the excellence of the proposed method. In addition, composition-structure-property linkages were constructed over a wide range of compositions, based on the analysis results of the high-throughput synthesized samples. The #4 (Fe53.9Co16.8Cr11.7Ni11.5Mo6.0) and #7 (Fe52.9Co16.1Cr12.8Ni12.5Mo5.6) samples exhibited the highest hardness levels while maintaining an FCC single-phase structure. These selected compositions were fabricated in bulk samples, and tensile testing of bulk samples revealed that Fe53.9Co16.8Cr11.7Ni11.5Mo6.0 demonstrated superior tensile properties with improved strain hardening behavior, identifying it as optimized composition. This study offers valuable insights to advance the development of novel alloys through high-throughput synthesis methods.http://www.sciencedirect.com/science/article/pii/S2238785425014243In-situ alloyingDirect energy depositionHigh-throughput synthesisMedium-entropy alloyComposition-structure-property linkages |
| spellingShingle | Jae Heung Lee Ji Yeong Lee Bon Woo Koo Dae-Kyeom Kim Jungwan Lee Eun Seong Kim Hyojeong Ha Taek-Soo Kim Hyoung Seop Kim Accelerated discovery and testing of Fe–Co–Cr–Ni–Mo ferrous medium-entropy alloys: advanced in-situ alloying via direct energy deposition Journal of Materials Research and Technology In-situ alloying Direct energy deposition High-throughput synthesis Medium-entropy alloy Composition-structure-property linkages |
| title | Accelerated discovery and testing of Fe–Co–Cr–Ni–Mo ferrous medium-entropy alloys: advanced in-situ alloying via direct energy deposition |
| title_full | Accelerated discovery and testing of Fe–Co–Cr–Ni–Mo ferrous medium-entropy alloys: advanced in-situ alloying via direct energy deposition |
| title_fullStr | Accelerated discovery and testing of Fe–Co–Cr–Ni–Mo ferrous medium-entropy alloys: advanced in-situ alloying via direct energy deposition |
| title_full_unstemmed | Accelerated discovery and testing of Fe–Co–Cr–Ni–Mo ferrous medium-entropy alloys: advanced in-situ alloying via direct energy deposition |
| title_short | Accelerated discovery and testing of Fe–Co–Cr–Ni–Mo ferrous medium-entropy alloys: advanced in-situ alloying via direct energy deposition |
| title_sort | accelerated discovery and testing of fe co cr ni mo ferrous medium entropy alloys advanced in situ alloying via direct energy deposition |
| topic | In-situ alloying Direct energy deposition High-throughput synthesis Medium-entropy alloy Composition-structure-property linkages |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425014243 |
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