Influence of HEA reinforcement on pulse electric current sintered Aluminium Composites: Microstructure, Density, and nanomechanical properties

• Pulse Electric Current Sintering effectively consolidate HEA-reinforced Al matrix composites, with enhanced microstructure. • Increased HEA content slightly reduces density but maintains high overall densification. • The addition of HEA reinforcement significantly enhances nanohardness and elastic modulus of aluminium composites. • HEA addition refines microstructure, leading to improved composite mechanical properties. This study investigates how different compositions of high-entropy alloys (HEAs), known for their strength and thermal stability, affect the microstructure, density, and nanomechanical properties of aluminium matrix composites produced by pulse electric current sintering (PECS). Commercial aluminium was reinforced with 5%, 7%, and 10% HEA and sintered using PECS. Microstructural analysis showed improved particle bonding and dispersion, resulting in enhanced mechanical properties. Although relative density slightly decreased with higher HEA content, there was a significant enhancement in nanohardness and elastic modulus. The composites exhibited improved resistance to plastic deformation and increased stiffness, thus, highlighting the effectiveness of HEA reinforcement in optimizing aluminium composites for high-strength, lightweight, and advanced engineering applications. These findings offer valuable insights for developing next-generation materials suited to demanding engineering environments.