Effect of process parameters on AlCoCr2FeMo0.5Ni high-entropy alloy coatings produced using laser directed energy deposition

In the aerospace sector, High-Entropy Alloys (HEAs) are emerging as promising alternatives to nickel superalloys for turbine components due to their exceptional thermal stability, fatigue strength, and corrosion resistance. HEAs, composed of five or more elements in near-equal proportions, typically form stable crystal structures. Additive manufacturing, notably Laser Directed Energy Deposition (L-DED), addresses the limitations of conventional fabrication methods. In this study, L-DED was used to print the AlCoCr2FeMo0.5Ni HEA to produce defect-free deposits with strong substrate adhesion. Single-track and multi-track tests assessed the impact of laser power, scanning speed, and powder feed rate on defects, with optimal conditions identified through optical microscopy. SEM analysis provided insights into the microstructure and composition, while 3D mapping characterized the surface morphology and roughness. The results demonstrate the potential of L-DED for advanced HEA manufacturing.