Microstructural and Mechanical Evolution in High-Entropy Alloys: A Comprehensive Review of Applications and Research Challenges
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Author list: Pradeep Kumar, J.; Manova, S.; Uthaisangsuk, V.; Godson Asirvatham, L.G.; Wongwises, S.
Publisher: Springer
Publication year: 2025
ISSN: 1598-9623
eISSN: 2005-4149
Languages: English-Great Britain (EN-GB)
Abstract
The fundamental theory of utilizing multiple principal elements in high concentrations, has created a novel class of promising materials known as high entropy alloys (HEAs). Unlike standard metallic system, that consists of only one or two primary elements, HEAs posses several primary components in near-equal ratios, leading to unique microstructures and better performance in extreme environments. While there are several well-established processing techniques for conventional alloys, the different synthesis procedures for multicomponent alloys utilised in industrial applications need to be examined more closely. This review article provides a comprehensive overview of the fundamental concepts and sub-categories of HEAs. It further emphasizes the various fabrication techniques and highlights the key findings related to the mechanical evolution of HEAs. In addition to that, the review article explores major research gaps based on the existing literatures. Also, it highlights various fabrication techniques such as additive manufacturing process to develop complex HEA structures and by providing in situ microstructural optimization. The fabrication of HEAs faces several challenges like elemental segregation, phase stability, and process scalability. However, ongoing advancements in alloy design, modelling, and optimization are addressing these issues, facilitating for their usage in industries like aerospace, automotive, and energy. Based on the analysis of the tensile characteristics of HEAs, it was observed that deformation mechanisms such as phase interactions and dislocation slip predominantly contribute to enhancing the mechanical performance of the alloy. Fractography study reveals that the fracture mode depends mainly on phases in particular, FCC shows ductile fracture while B2 tends to fracture in a brittle. Compared to conventional alloys, HEAs exhibit improved hardness, due to solid lattice distortion and solid solution strengthening mechanism as dominant mechanisms. Accordingly, this review clearly highlights the existing research gaps and provides well-defined future recommendations. © The Author(s) under exclusive licence to The Korean Institute of Metals and Materials 2025.
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