Structure and Phase Transformations in Gas Atomized AlCoCrFeNi High Entropy Alloy Powders

In this study, the crystal structure and phase stability of gas atomized equiatomic AlCoCrFeNi powder was investigated. This alloy is usually described as a high entropy alloy forming a solid solution phase stabilized by a high mixing entropy. However, thermodynamic calculations show that the high entropy phase is stable only at very high temperatures close to the melting point and that a mixture of several phases are the most stable state at lower temperatures. This suggest that kinetic effects may influence the phase composition of atomized powder. The unique features of X-ray diffraction, neutron diffraction as well as transmission electron microscopy were used to study the atomic structure of the atomized powder in detail. The results show that the powder crystallises in an ordered B2 (CsCl-type) structure with a preferred site occupation of Al and Fe on the (½ ½ ½) position and Co and Ni on the (0 0 0) position. During heat-treatment of the powder, the B2 phase decomposes into fcc and σ phases and the final phase composition is highly dependent on the heating rate. The effect of heat-treatment on the atomized powder was also investigated and revealed a significant phase transformation with e.g. the formation of σ phase preferably at the surface of the powder particles. The phase content was also dependent on the size fraction of the powder particles. Sintering of green bodies made with different heat cycles showed that the phase composition of the starting material had a significant impact on the final phase composition and microstructure of the sintered components. The results illustrate the importance of well-defined powder materials for powder consolidation, especially additive manufacturing (binder jetting) of high entropy alloys