Cooling Rate and Compositional Effects on Microstructural Evolution and Mechanical Properties of (CoCrCuTi)100−xFex High-Entropy Alloys

This study investigates the impact of cooling rate and alloy composition on phase formations and properties of (CoCrCuTi)100−xFex (x = 0, 5, 10, 12.5, 15) high-entropy alloys (HEAs). Samples were synthesized using arc-melting and electromagnetic levitation, followed by quenching through the use of a Cu chill or V-shaped Cu mold. Cooling rates were evaluated by measuring dendrite arm spacings (DASs), employing the relation DAS = k ɛ−n, where constants k = 16 and n = ½. Without Fe addition, a microstructure consisting of BCC1 + BCC2 phases formed, along with an interdendritic (ID) FCC Cu-rich phase. However, with the addition of 5–10% Fe, a Cu-lean C14 Laves phase emerged, accompanied by a Cu-rich ID FCC phase. For cooling rates below 75 K/s, alloys containing 10% Fe exhibited liquid phase separation (LPS), characterized by globular Cu-rich structures within the Cu-lean liquid. In contrast, for the same composition, higher cooling rates of 400–700 K/s promoted a dendritic/interdendritic microstructure. Alloys with 12.5–15 at. % Fe displayed LPS irrespective of the cooling rate, although an increase in uniformity was noted at rates exceeding 700 K/s. Vickers hardness and fracture toughness generally increased with Fe content, with hardness ranging from 444 to 891 HV. The highest fracture toughness (5.5 ± 0.4 KIC) and hardness (891 ± 66 HV) were achieved in samples containing 15 at. % Fe, cooled at rates of 25–75 K/s.