Design and Production of a New FeCoNiCrAlCu High-Entropy Alloy: Influence of Powder Production Method on Sintering

The structure of FeCoNiCrAl1.8Cu0.5 high-entropy alloys (HEA) obtained by two different routes has been studied. The selection of the composition has followed the Hume–Rothery approach in terms of number of itinerant electrons (e/a) and average atomic radius to control the formation of specific phases. The alloys were obtained either from a mixture of elemental powders or from gas-atomised powders, being consolidated in both cases by uniaxial pressing and vacuum sintering at temperatures of 1200 °C and 1300 °C. The characterization performed in the sintered samples from both types of powder includes scanning electron microscopy, X-ray diffraction, differential thermal analysis, and density measurements. It was found that the powder production techniques give similar phases content. However, the sintering at 1300 °C destroys the achieved phase stability of the samples. The phases identified by all techniques and confirmed by Thermo-Calc calculations are the following: a major Co-Ni-Al-rich (P1) BCC phase, which stays stable after 1300 °C sintering and homogenising TT treatments; a complex Cr-Fe-rich (P2) B2 type phase, which transforms into a sigma phase after the 1300 °C sintering and homogenising TT treatments; and a very minor Al-Cu-rich (P3) FCC phase, which also transforms into Domain II and Domain III phases during the heating at 1300 °C and homogenising TT treatments.