Microstructure and Mechanical Behavior Comparison between Cast and Additive Friction Stir-Deposited High-Entropy Alloy Al0.35CoCrFeNi

High-entropy alloys (HEAs) are new alloy systems that leverage solid solution strengthening to develop high-strength structural materials. However, HEAs are typically cast alloys, which may suffer from large as-cast grains and entrapped porosity, allowing for opportunities to further refine the microstructure in a non-melting near-net shape solid-state additive manufacturing process, additive friction stir deposition (AFSD). The present research compares the microstructure and mechanical behavior of the as-deposited AFSD Al0.35CoCrFeNi to the cast heat-treated properties to assess its viability for structural applications for the first time. Scanning electron microscopy (SEM) revealed the development of fine particles along the layer interfaces of the deposit. Quasi-static and intermediate-rate compression testing of the deposited material revealed a significant strain-rate sensitivity with a difference in yield strength of similar to 400 MPa. Overall, the AFSD process greatly reduced the grain size for the Al0.35CoCrFeNi alloy and approximately doubled the strength at both quasi-static and intermediate strain rates.