Rapid Consolidation and Mechanical Characterization of High-Entropy Particle-Reinforced Al-Cu-Mg Composites Through High-Frequency Induction Hot Sintering

High-entropy alloys (HEAs) and refractory high-entropy alloys (RHEAs) have received considerable attention as innovative reinforcements to replace traditional ceramics in lightweight matrices. However, understanding how different high-entropy systems interact under ultra-fast consolidation pathways remains an open challenge. This study compares conventional sintering (CS) and high-frequency induction hot sintering (HFIHS) in an Al-4.5Cu-1.5Mg matrix reinforced with AlCoCrFeNiTi (HEA) and WMoTaNbV (RHEA) particles at various concentrations, enabling a direct comparison of both reinforcement types under identical processing conditions. Results show that HFIHS achieves near-theoretical densification within minutes while restricting atomic mobility and precipitate coarsening through sustained pressure and short thermal exposure. Furthermore, the study observes a clear strengthening dependence on reinforcement content, with the HEA system exhibiting unexpectedly superior mechanical performance and load-bearing capacity compared to the RHEA. Finally, the correlations between ultra-fast sintering, phase evolution, and strengthening mechanisms are discussed, highlighting HFIHS as a promising route for developing high-strength lightweight composites.