High-Entropy Alloy Structure With Uniform Composition in 3D Printing
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Solution Overview
Problem
High-entropy alloys face challenges in achieving uniform element composition distribution and mechanical strength, especially when forming large structures, due to issues with melting and cooling rates, leading to difficulties in securing high-temperature strength and corrosion resistance.
Innovation Solution
The development of a method for producing high-entropy alloy structures using additive manufacturing, where a high-entropy alloy powder with a specific element composition is used to create a solid solution phase with a face-centered cubic or body-centered cubic lattice structure, ensuring uniformity and high mechanical strength through precise control of atomic ratios and processing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional melting and casting methods are used to produce high-entropy alloy structures, then large structures can be formed, but uniform element composition distribution and mechanical strength cannot be achieved due to uneven melting and cooling rates
Solution Approach 1:
The patent changes the fundamental processing parameters from conventional melting/casting to additive manufacturing with layer-by-layer deposition. This transforms the melting rate and cooling rate parameters to achieve uniform element composition distribution while forming large structures, resolving the contradiction between manufacturing precision and process complexity
Solution Approach 2:
The patent segments the manufacturing process into layer-by-layer additive manufacturing steps, where each layer is deposited and solidified sequentially. This segmentation allows precise control of melting and cooling rates in each layer, achieving uniform element composition distribution throughout the entire structure without requiring complex global control
2Manufacturing precision
If additive manufacturing is used to produce high-entropy alloy structures, then uniform element composition distribution and mechanical strength can be achieved, but the process requires precise control of atomic ratios and processing conditions
Solution Approach 1:
The patent uses equiatomic ratio high-entropy alloy powder as the starting material, ensuring homogeneous composition from the beginning. This homogeneity simplifies the manufacturing process by eliminating the need for complex post-processing to achieve uniform element distribution, making the process more easier to control while maintaining high manufacturing precision
Solution Approach 2:
The patent replaces conventional mechanical mixing and casting methods with additive manufacturing technology that uses digital modeling and precise material deposition. This substitution enables automatic control of atomic ratios and processing conditions through software control, improving ease of manufacture while maintaining uniform mechanical strength
3Manufacturing precision
If high-entropy alloy powder with equiatomic ratio is used in additive manufacturing, then solid solution phase with uniform element composition can be formed, but the atomic diffusion rate is slow affecting heat treatment effectiveness
Solution Approach 1:
The patent performs preliminary action by forming the solid solution phase with uniform element composition distribution during the additive manufacturing process itself, before heat treatment is applied. This preliminary uniformity compensates for the slow atomic diffusion rate during subsequent heat treatment, ensuring the final product achieves the desired reliability and properties
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the creation of alloy structures with high uniformity in element composition and mechanical strength, suitable for severe environments, with improved high-temperature strength and corrosion resistance, and the ability to form complex shapes.
Implementation Method 1
the heating unit locally heats and melts the alloy powder to form a liquid phase
Implementation Method 2
a solid solution phase is formed by solidifying the melted alloy powder
Data Source
Figure 1(a)~1(g)
Figure 2(a)~2(c)
Figure 3(a)~3(i)
AI summary
Provided is an alloy structure with an arbitrary shape dimension which has high uniformity in the distribution of the element composition and the mechanical strength and excellent high-temperature strength and corrosion resistance. The alloy structure contains Fe and at least four elements, which are selected from the group consisting of elements from atomic number 13 to atomic number 79 included in Group 3 to Group 16 of the periodic table of the elements and have a ratio of the atomic radius to an Fe atom of 0.83 or more but 1.17 or less, each of Fe and the four elements is contained in an atomic concentration range of 5 at% or more but 30 at% or less, a difference in atomic concentration between at least four elements among the at least four elements and Fe is in a range of less than 3 at%, and the alloy structure has, as a main crystal, a column crystal in which the at least four elements and Fe are solid-dissolved.