acsm_48.01_15
acsm_48.01_15
Copyright: ©2024 The authors. This article is published by IIETA and is licensed under the CC BY 4.0 license
(http://creativecommons.org/licenses/by/4.0/).
https://doi.org/10.18280/acsm.480115 ABSTRACT
Received: 31 August 2023 Modern mechanical applications demand robust materials with boosted mechanical
Revised: 14 October 2023 properties capable of resisting challenging working conditions. Single substances and
Accepted: 10 January 2024 pure material might fail to meet all application requirements translated by larger
Available online: 26 February 2024 robustness and endurance. Correspondingly, scholars developed functional substances
recognized with high-energy alloys (HEAs) with upgraded strength, durability, and
corrosion behavior. Nonetheless, the available literature requires further research that
Keywords: provides sufficient insights pertaining to HEAs’ contributions. Consequently, this
high-entropy alloys, strength, corrosion research is guided, aiming to bridge this knowledge gap by exploring the contributory
resistance, challenging operating conditions, merits and valuable benefits of HEAs when engaged in challenging operating
material innovation, thermal stability, circumstances. The article addresses the promising HEA gains, their leading features,
structure-property relationships relevant properties, and diversified applications. The method adopted in this work
comprises a scoping review through which multiple peer-reviewed articles and recent
publications (2003 to 2023) were surveyed, addressing contributory gains of HEAs in
fulfilling enhanced mechanical performance for different applications. Based on the
scoping overview led in this paper, it was found that HEAs could serve in multiple
engineering areas under challenging working conditions owing to their practical
properties, namely elevated hardness, augmented mechanical strength, amended fatigue
resistance, elaborated ductility, optimal toughness, superior microstructure stability at
high temperatures, and exceptional wear resistance, considerable corrosion resistance,
and boosted oxidation resilience. Accordingly, these excellent characteristics enable their
broad implementation in vital engineering disciplines and arduous practices, notably
aviation, automotive, maritime, energy storage systems (ESSs), and additive
manufacturing. Additionally, the review outcomes revealed that mixing multiple
elements together with numerous crystal structures could provide significant strength-to-
weight ratios, helping exhibit various potent features compared with traditional alloys.
In light of this framework, the implications of this research are mirrored by focusing
more attention on the consequential engineering influences and feasible practicalities of
HEAs to promote their extensive utilization in multiple domains, allowing supportive
qualities and advantageous effects on entire material characteristics to each application
they are engaged in. From this perspective, it is suggested to manage additional research
processes to classify vital gains of HEAs and elucidate their added value.
125
Figure 1. The classification of HEAs with other materials in terms of length scale and structural and chemical complexity level
[10]
1.1 HEA evolution and corresponding useful features aluminum, copper, ferrous, magnesium, or titanium. HEAs
were developed in 1995 utilizing an innovative alloy design
idea [13]. This area of study was examined using early theories.
However, these alloys had complex microstructures and
uninteresting characteristics in different circumstances [14].
Publications on HEAs have increased globally after various
intriguing features were noticed globally in the initial research,
as shown in Figure 2.
A 2003 research published in the HEA field is relevant even
if it doesn’t provide any results since it teaches important HEA
ideas beautifully and emotionally [12]. It was not until Yeh et
al. [15] and Candor et al. [16] separately began researching
multiple-element alloys in 2004.
HEA systems, such as Al-Co-Cr-Cu-Fe-Ni, Co-Cr-Cu-Fe-
Ni-Ti, Al-Co-Cr-Cu-Fe-Ni-B, Al-Co-C, and Al-Co-Cr-Cu-Fe-
Ni-V offer excellent characteristics such as high hardness and
strength, excellent wear resistance, high-temperature strength,
good structural stability, limited diffusion, oxidation
Figure 2. Number of HEA system-related articles published resistance over conventional alloys since [17] first discovered
up until 2015 [11] them. Afterwards, HEAs became an essential topic in material
science. In several technical industries, including aerospace,
HEAs have recently been added as a new branch to the energy, transportation, and manufacturing, advanced levels of
metallic alloy tree. They can be featured as alloy systems potency, robustness, efficiency, and durability have been
involving five or more primary alloying components or have a demanded in materials. To fulfil the increasing needs posed by
mixture entropy higher than 1.5R [11]. Despite the initial operating circumstances in these high-end applications, new
appearance that they could produce extremely complex materials have been investigated. Traditional commercial
microstructures with multiple phases, intermetallic alloys are capable of performing these tasks, but they have
compounds, and segregations, making them difficult to drawbacks such as low specific weight and high density,
understand and analyze, these innovative materials have which have an adverse effect on structural applications [11].
typically simple crystal structures like face-centered cubic These characteristics contribute to significant benefits in a
(FCC) and body-centered cubic (BCC) due to the broad range of applications. Recently, there has been a lot of
thermodynamics applied to a multi-component system. The interest in HEAs. A new frontier in metallic materials has been
first information in 2004 saw the publication of high entropy formed by developing more than 300 HEAs so far. The
crystalline alloys—roughly 19 years ago [12]. Since ancient connections between phase, microstructure, and mechanical
times, most alloy design has only been adding minor elements characteristics are the subject of most HEA investigations.
to alter the properties of a primary metal element, such as Although HEAs’ physical characteristics received less
126
attention, they are highly promising. For instance, the study systems is well understood, yet little is known pertaining to
[18] provided a brief evaluation of current knowledge about these systems themselves. This paper looks at the development
the mechanical, thermal, and physical attributes of HEAs. Iron of HEAs, their characteristics, and their present and future
is the primary component of steel alloys, whereas nickel and applications.
cobalt are the primary components of superalloys. According A quarter of the mass of the Earth is made up of metals,
to the initial definition given to HEAs, these substances which make up around two-thirds of all the elements. Because
represent a novel type of metallic systems that contain at least they seldom exibit a favorable mix of qualities for thermal,
five distinct principle elements. The term “principal elements” structural, and other mechanical purposes, metals are rarely
refers to materials that account for at least 5% of the content employed in their pure form. By adding other elements to the
of an alloy. The ratios between the primary components are pure metal, this property restriction is removed. Solute
mole ratios or very near to them, and the content of the main addition to a single base is the foundation of conventional
element’s ranges from 5% to 35%, while that of the minor alloys. The selection of one or two critical elements in created
components is less than 5% [19]. Their projected level of alloys is dependent on the qualities needed for the alloy’s
mixing entropy was utilized as the basis for the second purpose. Excellent strength alloys with high thermal stability
notation adopted to describe their conception. The concept of at elevated temperatures are frequently required [20].
HEAs has also been referred to as the entropy of mixing.
Any alloy with a configurational entropy value higher than
1.5R qualifies as a HEA by this criterion [11]. The multiple 2. HEA’S FOUR CORE EFFECTS
HEA categories have led to some misunderstanding, which
urged discussions respecting which alloys are within the HEA Owing to each component’s equimolar concentration, HEA
umbrella. In one of the early papers, HEAs are predominantly compositions are more complicated than those of ordinary
depicted as “those comprising of five or more primary alloys. HEAs have various distinct kinetic and thermodynamic
elements in equimolar ratios” according to a composition- features because of the revolutionary alloy design idea and
based definition. HEAs can also include small elements to high-concentration solid solution structure which enables the
modify the characteristics of the original HEA and produce development of distinctive and functional properties [21].
more HEAs. The amount of entropy is not constrained by this According to the studies [11, 22, 23], the four core effects of
composition-based approach, which gives elemental HEAs can be summarized by the following aspects:
concentrations. Therefore, this idea does not need the (1) High-entropy processes known as hermodynamics allow
existence of a single-phase SS [12]. a material to form simpler solid solution phases,
The term “high entropy” serves as a catalyst for a definition frequently FCC and BCC.
based on the quantity of entropy. The distinction between (2) The kinetics of microstructural level processes, including
alloys with low, medium, and high entropy is thus made using creep, grain development, and recrystallization are
a separate concept. The Boltzmann equation provides an easy reduced by slow diffusion.
way to describe solid solution strengthening (SSS), ideal from (3) Severe lattice distortion enhances the chemical and
alloy composition, nevertheless necessitates that atoms mechanical characteristics of structures.
occupy arbitrary lattice locations. This idea also suggests an (4) The interaction between the various elements improves
alloy’s configurational entropy has a fixed value. The entropy the alloy’s characteristics in comparison to those that
of an alloy can, nevertheless, vary with temperature. The would be predicted from the law of mixes, which is how
effects of temperature can be minor, like a very slight change cocktail effects may be described on an atomic scale.
in the short-range atomic ordering, or they can be large, like The specifics of each consequence will be covered. The four
chemically separating the product and parent phases during a main impacts and their connection to microstructure and
first-order phase shift. The entropy-based concept makes the characteristics are summarized in Figure 3 [14].
assumption that the alloy may be characterized by “liquid
solution and high temperature solid solution states where the
thermal energy is substantial enough to cause separate
elements to have random positions within the structure” to
address these problems. This aspect indicates that such a
scenario is only possible at extremely high temperatures or
when the alloy is liquid and characterizes an alloy using its
most outstanding level of entropy. At the melting temperature,
the atomic positions in binary metallic liquids are not
necessarily random. This feature is consistent with earlier
research that suggested metallic treatments are frequently not
the best option. These issues make it challenging to apply this
definition. Commercially available alloy systems are based on
either aluminum, nickel, iron, or copper in the case of
superalloys.
Nonetheless, the variety of alloys that can be made using
these traditional alloy processes is limited. New alloys called
“high entropy alloys” were developed at the beginning of the
millennium. These alloys were made using equiatomic
substitution, which entails substituting near-equiatomic or
multi-component equiatomicmixes of chemically similar Figure 3. Four core effects and their relationships [14]
species for individual components. The behavior of binary
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2.1 High entropy effect atoms’ constituents, which leads to hardening, and the
electronic structures linked to variations in local bond states,
Basic structures like FCC and BCC have a lower Gibbs for example, may have an impact on thermal and electrical
energy when all the components are present because there is a conductivities [12, 32, 33].
high number of unique elements in the mixture, which leads to
a high mixing entropy. More solution phases arise in this way 2.4 The ‘cocktail’ effect
under conditions of high entropy. These high entropy phases
are stabilized by this Gibbs energy reduction, leading to a
simple microstructure [11]. According to the studies [24, 25],
the high configurational entropy impact promotes the creation
of solid solutions while impeding phase transformations that
would otherwise affect the system’s thermodynamics [26].
Different binary to septenary alloys’ XRD patterns are
displayed in Figure 4. The concept that both ternary and binary
compounds would evolve defies such primary structural forms
[27].
Because of the significant entropy influence, HEAs consist Tying together composition, microstructure, and property
of a single matrix, whether an FCC, BCC, or other structure. data provides new challenges in the research of HEAs. The
As a result, each component joins the whole. The resulting quantity of alloys which must be significantly defined grows
solid solution’s lattice is severely deformed since each element due to the wide range of compositions. In light of the fact that
has a unique atomic size, bonding energy with other elements, components are usually more localized in HEAs than in
and inclination toward crystal formation. Lattice distortion traditional alloys, regardless of the same alloy family,
affects the final properties of the alloys, such as their hardness changing just one element can considerably impact
and tensile strength, because it inhibits dislocations from microstructure and characteristics. Accordingly, the following
freely migrating as expected [30, 31]. Another significant section will examine HEA’s physical (electrical and magnetic),
result is that the features’ dependence on temperature is mechanical, and thermal properties.
reduced [11, 24]. Mismatch in shear modulus between the
128
3.1 Electrical properties and Co results in increased magnetization. Like conventional
magnetic materials, higher coercivities are associated with
For the same composition, the FCC phase has a larger finer microstructures [41].
electrical resistivity than the BCC phase, and the linear
average of the volume fractions of the BCC and FCC phases 3.3 Thermal properties
determines the electrical resistivity in a two-phase field. For
instance, the usual range of electrical resistivity for Thermal conductivity, K (T), is frequently determined by
AlxCoCrFeNi alloys (0 × 2) is 100-200 cm. The electrical measuring a material’s density, specific heat, and thermal
resistance of each of these alloys rises with a linear trend with diffusion coefficient (T). The region with the lowest thermal
temperature. A non-monotonic electrical resistivity conductivity is the FCC + BCC duplex [22]. Low Al
dependence could result from the microstructures switching concentration single-phase FCC alloys have a thermal
from “FCC” to “BCC” as the Al content rises. Electrical conductivity almost half that of high Al content (single-phase
resistivity is predicted to rely monotonically no longer on Al BCC alloys). As Al concentration rises in single-phase zones,
concentration with the switch from BCC to FCC the thermal conductivity falls. Lattice distortions and an
microstructures. Cold-rolled Comparing homogenized improved phonon mean free path brought on by lattice thermal
materials to cold-rolled alloys, resistance is increased [37-39]. expansion at elevated temperatures are thought to be the
causes of these events [42, 43].
3.2 Magnetic properties
3.4 Mechanical properties
To prevent materials from being strained by an external
magnetic field, the magnetostriction effect must be very Composition and microstructure have a significant impact
modest. Relying on the number of current magnetic on mechanical characteristics. While flaws are essential
components, HEA’s magnetic characteristics could be microstructural elements that substantially affect mechanical
modified. Processing and thermal history have an impact on properties, the composition determines elastic characteristics
magnetic characteristics through the phases that are created. and atomic interactions that determine dislocation behaviors
Compared to annealed materials, as-processed materials [12, 44].
frequently have unique microstructures and magnetic
characteristics [12, 40]. 3.4.1 Hardness
Investigations on the magnetic characteristics of HEAs have Other factors should be considered to understand this wide
mainly concentrated on alloys made of Cr, Co, Al, Cu, Ni, Ti, range of hardness ratings. Whether the sample was produced
and Fe. Higher magnetization often represents the result of utilizing liquid-state or solid-state processing will impact the
having more magnetic elements. However, adding manufacturing procedure [45, 46].
components to alloys can have a considerable influence. For The hardness of an alloy depends on its constituent parts,
instance, magnetization is decreased when Cr is added. The how they interact with one another and other properties. Figure
conclusion reached by Zhang et al. [26] that the presence of Cr 6 depicts that most HEAs have harder surfaces than standard
causes the cancellation of magnetization appears to be alloys [47].
supported by the observation that the separation of Cr from Fe
Figure 6. Hardness extremes and minimums of the most researched HEA systems [11]
129
3.4.4 Creep resistance resistance, and oxidation behavior features [12, 52].
In high-temperature applications, creep is crucial because it
behaves in line with the potential law when the temperature is 3.5 Functional properties
high enough to allow dislocation movement but the viscous
law when it is low enough to prohibit it. Often, HEAs show HEAs are recently created materials for which the study has
significant creep resistance [46]. only focused on the mechanical and microstructural aspects.
On the functional qualities of the HEAs, some improvement is
3.4.5 Wear resistance seen. These attributes include soft-magnetic properties,
Wear is a significant issue since HEAs exhibit greater radiation resistance, catalytic properties, and thermoelectric
competitiveness and the ability to be used in tools, molds, and qualities. These traits are influenced by their unique multi-
structural components. principal element solid solution structure. The functional
Both sticky and abrasive environments have been examined features are crucial for applications such as electromagnetic
to determine how HEAs wear [22]. The Co 1.5CrFeNi1.5Ti and interference shielding, nuclear magnetic resonance, and solar
Al0.2Co1.5CrFeNi1.5Ti alloys, according to Chuang et al. [48] plates. Examples of materials that help store hydrogen duels
exhibit more wear resistance than normal wear-resistant steels include CoFeMnTiVZr, TiZrNbMoV, HfNbTiVZr, and
of the same hardness. These HEAs’ extraordinary anti- ZrTiVCrFeNi because they provide greater bulk density,
oxidation and thermal softening resistance are thought to play increased safety, and reversibility in gas storage and sensing
a substantial role in their outstanding wear resistance. Alloying applications [14].
has the potential to affect the wear properties of HEAs [49]. Soft magnetic materials [53-55] irradiation resistance
materials [56-59], superconducting materials [60],
3.4.6 Fatigue behavior photothermal conversion materials [61, 62], diffusion barrier
One of the most important variables that must be addressed films [63, 64] are only a few of the functional areas where
and investigated in many prospective applications for HEAs is HEAs have made significant strides.
fatigue behavior and lifespan prediction, whether we are
looking for use in the aerospace sector or other domains. In
their investigation of the Al0.5CoCrCuFeNi HEA’s fatigue 4. OPERATING AT SEVERE WORKING EVENTS
behavior, Hemphill et al. [50] compared the results to those of
other popular alloys, such as titanium alloys, advanced BMGs, In alloy engineering, the ideal alloy has a low density and
and steels. Compared to steel, titanium, and nickel alloys, the high strength/ hardness [65]. In construction purposes like
bottom limit of the HEA fatigue ratios performs better than civil transportation and aeronautical engineering, lowering the
several Zr-based BMGs and zirconium alloys. Moreover, due weight of engineering elements is essential for reducing
to their brittle nature, some materials, such as wrought energy demand. Without HEAs, an aircraft corrodes, oxidizes,
aluminum alloys and ultra-high-strength steels, have lower and cannot withstand extremely considerable temperatures
fatigue ratios despite having higher tensile strengths. [66]. Under typical operating conditions, power plants without
HEAs as fuel cladding materials exhibit low thermal
3.4.7 Corrosion resistance conductivity, a high thermal neutron absorption cross-section,
According to Zhang et al. [22] and Heydari et al. [51], HEAs and corrosion [67, 68].
have excellent corrosion resistance. For starters, high entropy An air foil bearing is an example of a part used at high
alloys have better corrosion resistance than several commonly temperatures but not requiring liquid lubrication. The system,
used stainless steel types because their crystal structures tend which holds up the rotating shaft, comprises a top and a bump
to be simpler. Another factor is that many high entropy alloys foil. The top foil and the journal, which are in touch with the
have dendritic segregation structures, comprising a basic body shaft when it is stationary, are separated by a thin layer or gap
structure and surface structure. Dendritic segregation when moving at higher speeds because of hydrodynamic
structures also contain multiple disordered structures and pressure [69]. As a result, the bearing strikes the race at a slow
nanoparticles. Introducing these structures has considerably rate during startup acceleration at standard temperature and
increased the corrosion resistance of high entropy alloys. For shutdown deceleration at high temperature. These working
instance, the considerably increased CoCrFeSi displayed circumstances are unpredictable. Thus, the materials must
improved corrosion resistance compared with stainless steel provide lubricity throughout a wide temperature range and
304 in 1.0 mol/L NaCl and 0.5 mol/L H2SO4 solutions at long duration. A gas turbine engine’s rolling element bearing
ambient temperature [19]. and the bearing and piston of an automobile diesel engine all
function at high temperatures similarly to air foil bearings [70].
3.4.8 Density Similar to gas turbine engines to work efficiently (requiring
For many applications, alloy density is a crucial factor to higher temperatures, faster speeds, and higher contact
consider. The densities of conventional alloys are frequently pressures), the design and operating circumstances of
grouped according to the weights of the constituent elements: mechanical systems must be drastically revised [71-74].
2.7 g/cm3 for aluminum alloys, 4.5 g/cm3 for titanium alloys,
7.9 g/cm3 for steels, and 8 to 9 g/cm3 for superalloys based on 5. APPLICATIONS OF HIGH ENTROPY ALLOYS
nickel. Density is more equally distributed for CCAs. Light
metal CCAs range in density from (2.67-5.21) g/cm3, while The unique properties of HEAs have sparked a lot of interest
refractory CCAs range from 5.59 to 13.75 g/cm 3. For MPEAs in mechanically and functionally orientated materials. A
made of 3D transition metals, densities aren’t typically prospective future goal for HEAs is to design and build
measured. They normally range between 5.1 and 8.9 grams per potential special applications to satisfy new requirements as
cubic centimeter, under a weighted mixing rule. As a result, opposed to merely replicating current performance [75].
HEAs have favorable corrosion, electrochemical, wear- Several HEA implementations are displayed in Table 1.
130
Table 1. Various HEA applications
131
engineering disciplines. [14] Kumar, A., Singh, A., Suhane, A. (2022). Mechanically
alloyed high entropy alloys: existing challenges and
opportunities. Journal of Materials Research and
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