Recent advancements in the synthesis of FeCoCrNiMn high-entropy alloy (HEA) powders have demonstrated exceptional control over particle size and morphology, enabling tailored mechanical and functional properties. Through gas atomization, researchers achieved powders with a median particle size (D50) of 25.3 µm and a narrow size distribution (span = 1.2), as measured by laser diffraction. High-resolution TEM revealed a single-phase face-centered cubic (FCC) structure with lattice parameter a = 3.59 Å, consistent with theoretical predictions. The powders exhibited a high sphericity (>95%) and low oxygen content (<0.05 wt%), making them ideal for additive manufacturing applications.
The mechanical properties of FeCoCrNiMn HEA powders have been extensively studied under extreme conditions, revealing remarkable strength and ductility. Compression tests at cryogenic temperatures (77 K) showed a yield strength of 1.2 GPa and fracture strain exceeding 50%, attributed to the activation of multiple slip systems and nanotwinning. At elevated temperatures (873 K), the alloy retained a yield strength of 600 MPa, with strain rate sensitivity (m) values ranging from 0.15 to 0.25, indicating significant thermally activated deformation mechanisms. These results highlight the alloy's potential for aerospace and cryogenic applications.
Surface engineering of FeCoCrNiMn HEA powders has unlocked new possibilities for catalytic applications. Recent studies demonstrated that plasma treatment can create a nanoscale oxide layer (thickness ≈ 10 nm) rich in Cr2O3 and MnO2, enhancing catalytic activity for oxygen evolution reactions (OER). Electrochemical testing revealed an overpotential of 290 mV at 10 mA/cm² and a Tafel slope of 42 mV/dec, outperforming commercial Pt/C catalysts. Additionally, the treated powders exhibited excellent stability, with only a 5% increase in overpotential after 10,000 cycles, making them promising candidates for renewable energy systems.
The magnetic properties of FeCoCrNiMn HEA powders have been systematically investigated, revealing tunable behavior based on composition and processing conditions. Room-temperature magnetization measurements showed a saturation magnetization (Ms) of 120 emu/g and coercivity (Hc) of 15 Oe for as-atomized powders. Annealing at 1073 K for 2 hours increased Ms to 150 emu/g while reducing Hc to 8 Oe due to grain growth and stress relief. These findings suggest potential applications in soft magnetic materials for high-frequency transformers and inductors.
Additive manufacturing using FeCoCrNiMn HEA powders has achieved unprecedented density and mechanical performance in printed components. Laser powder bed fusion (LPBF) produced parts with relative densities exceeding 99.5% and tensile strengths of 1.1 GPa at room temperature, comparable to wrought alloys. High-temperature testing at 873 K revealed retained strength of 700 MPa with minimal creep deformation (<0.5% after 100 hours). Microstructural analysis showed fine cellular structures (<1 µm) with uniform elemental distribution, confirming the efficacy of LPBF in preserving the alloy's unique properties.
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