Additive manufacturing of TiB₂-containing CoCrFeMnNi high-entropy alloy matrix composites with high density and enhanced mechanical properties

Near-fully dense CoCrFeMnNi high-entropy alloy (HEA) matrix composites reinforced with 5 wt% TiB₂ nanoparticles were successfully additively manufactured via the laser-engineered net shaping technique. Compared to the monolithic CoCrFeMnNi printing process, a higher energy density input is shown to produce a synergic combination of Marangoni flow and capillary force in the laser-generated melt pool. It facilitates the enhancement of wettability, and hence a more uniform distribution of the reinforcement material and a high degree of densification of 99.72%, which are able to delay the early fracture of the material. The as-deposited composites exhibit improved yield strength, surpassing that of the monolithic HEA by 42%. The enhanced strength is mainly ascribed to dispersion strengthening. Besides, the refined grain size, the increased dislocation density, and the additional load transfer effect also contribute to the strength enhancement. Furthermore, the wear resistance properties of the CoCrFeMnNi/TiB₂ composite are also shown to be superior to those of the CoCrFeMnNi, indicating a decrease in friction coefficient by 22.4%. The enhanced tribological properties are attributed to the synergic effect of high-hardness and self-lubrication of TiB₂ nanoparticles. The findings provide guidelines for achieving high-performance HEA-matrix composites.