Harnessing metastability for grain size control in multiprincipal element alloys during additive manufacturing

Akane Wakai, Jenniffer Bustillos, Noah Sargent, Jamesa L. Stokes, Wei Xiong, Timothy M. Smith and Atieh Moridi ()
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Akane Wakai: Cornell University
Jenniffer Bustillos: Cornell University
Noah Sargent: University of Pittsburgh
Jamesa L. Stokes: NASA Glenn Research Center
Wei Xiong: University of Pittsburgh
Timothy M. Smith: NASA Glenn Research Center
Atieh Moridi: Cornell University

Nature Communications, 2025, vol. 16, issue 1, 1-10

Abstract: Abstract Controlling microstructure in fusion-based metal additive manufacturing (AM) remains a significant challenge due to the many parameters that directly impact solidification condition. Multiprincipal element alloys (MPEAs), also known as high entropy alloys, offer a vast compositional space to design for microstructural engineering due to their chemical complexity and exceptional properties. Here, we use the FeMnCoCr system as a model platform for exploring alloy design in MPEAs for AM. By exploiting the decreasing stability of the face-centered cubic phase with increasing Mn content, we achieve notable grain refinement and breakdown of epitaxial columnar grain growth. We employ a multifaceted approach encompassing thermodynamic modeling, operando synchrotron X-ray diffraction, multiscale microstructural characterization, and mechanical testing to gain insight into the solidification physics and its ramifications on the resulting microstructure of FeMnCoCr MPEAs. This work aims toward tailoring desirable grain sizes and morphology through targeted manipulation of phase stability, thereby advancing microstructure control in AM applications.

Date: 2025
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DOI: 10.1038/s41467-025-56616-0

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