Advancements in Laser Powder Bed Fusion of Non-WeldableSuperalloys: CoNi-Based High Entropy Superalloy

This research presents the development and characterization of an innovative CoNi-basedhigh entropy superalloy optimized for Laser Powder Bed Fusion (L-PBF) technology.Leveraging principles of high entropy alloys (HEAs), the alloy composition comprisingCo, Ni, Cr, Al, V, Ti, Ta, and W is tailored to meet the rigorous demands of sustainableapplications. Through a systematic investigation of process parameters, a processwindow is established to achieve parts with superior mechanical properties, includingtensile strength exceeding ۱ GPa and ductility exceeding ۳۰% at room temperature in asbuiltcondition. Additionally, compression tests reveal remarkable yield strengthretention up to ۷۰۰°C. Microstructural analysis (based on EBSD and TEM) confirms theformation of a single-phase fcc solid solution without any topologically close-packed(TCP) phases and remarkable segregation, highlighting the alloy's crack-resistant natureand high density achievable via L-PBF. The alloy's design principles, supported bycalculation of phase diagram (CALPHAD) using HEA database, underline its potentialfor high-performance component production in critical industries.