Optimizing the maximum strain of a laser-deposited high-entropy alloy using COMSOL multiphysics

Abstract Background Laser metal deposition (LMD) is a widely used additive manufacturing technique for producing complex high entropy alloys with special properties for several applications. The AlCoCrFeNiCu HEAs compositional design has six elements with a configurational entropy of 1.79 R and atomic concentrations between 5 and 35%, so the HEA system is thermodynamically favorable according to Boltzmann’s theory, attributed to the core effects. However, the high-entropy alloy has dominant Body-Centered Cubic structures which may be too brittle to be examined in tension experimentally. Preheating the substrate before and during layer deposition could be a potential solution that is currently under development since tensile loading necessitates an understanding of a material's behavior under tension through an analysis of its yield and ultimate tensile strength. A computer-aided design (CAD) solid model was used to generate the near-net dog-bone form of the alloy with moderately complicated geometrical characteristics using laser metal deposition (LMD) technology. This study investigates a straightforward and effective computational model for simulating material properties, using COMSOL Multiphysics 5.4 software for laser-deposited high entropy alloys that are excessively brittle to be tested in tension. The AlCoCrFeNiCu high-entropy alloy "dog bone" test sample was modeled using COMSOL Multiphysics for tensile loading. The first principal stresses and longitudinal strain under axial loading conditions were measured using a three-dimensional (3D) structural mechanics’ model. Results The results showed the ultimate tensile strength is 8.47 N/m 2 , attributed to the high entropy effect and the dominant phase structure of the alloy. Conclusion Numerical models in this paper demonstrate the effect of stresses on the tensile behavior of the AlCoCrFeNiCu high-entropy alloy. The model optimizes the LMD process by analyzing residual stresses and predicting tensile strength, thus, providing insights that show the potential of high entropy alloys for structural integrity in aerospace applications.