Microstructural Stability and Densification Behavior of Cantor-Type High-Entropy Alloy Processed by Spark Plasma Sintering

High-entropy alloys (HEAs) of the Cantor type (CoCrFeMnNi) are widely recognized as model systems for studying the relationships between composition, microstructure, and functional performance. In this study, atomized Cantor alloy powders were consolidated using spark plasma sintering (SPS) under systematically varied process parameters (temperature and dwell time). The densification behavior, microstructural evolution, and mechanical response were investigated using Archimedes’ density measurements, Vickers hardness testing, compression tests, scanning electron microscopy, and EDS mapping. The results reveal a non-linear relationship between sintering temperature and densification, with maximum relative densities obtained at 1050 °C and 1100 °C for short dwell times. Despite the ultrafast nature of SPS, grain growth was observed, particularly at elevated temperatures and extended dwell times, challenging the assumption that SPS inherently limits grain coarsening. All sintered samples retained a single-phase FCC structure with homogeneous elemental distribution, and no phase segregation or secondary precipitates were detected. Compression testing showed that samples sintered at 1060 °C and 1100 °C exhibited the highest strength, demonstrating the strong interplay between sintering kinetics and grain cohesion.