Synthesis of a self-reinforced powder material based on a high-entropy alloy

In this work, the formation of a self-reinforced HEA–WC powder material during the mechanical alloying (MA) of a mixture of elemental powders of the W-Fe-Co-Ni system in a planetary ball mill in a gasoline environment was investigated. X-ray diffraction (XRD), microstructural, and energy dispersive spectral (EDS) analysis revealed that after 20 hours of MA of the powders in a carbon-containing medium, a powder material based on a high-entropy alloy was formed. HEA based powder material contains two solid solutions with BCC and FCC crystal structure, as well as a carbide WC phase formed "in-situ" owing to the large negative value of the mixing enthalpy between carbon and tungsten. The “in-situ” formation of WC particles contributes to the enhancement of interfacial bonding with the metal matrix of the HEA. All phase components of the HEA–WC powder material are in the nanostructured state. The particles of the powder material have a close to spherical shape and a bimodal particle size distribution. The powder material consists of fine particles with a size of 1–10 μm and their agglomerates with a size up to 100 μm. The microstructure of the particles consists of the main gray phase of the BCC solid solution, dark spaces of the FCC solid solution and fine WC particles with a size of 0.1 μm to 1 μm evenly distributed in the HEA matrix. High-entropy alloys with the addition of carbon are promising in terms of practical application, because carbon, having a small atomic radius, dissolves as an interstitial element in the crystal lattice of the substitutional solid solutions of the HEA principal elements and, as a result, significantly affects their structure and phase composition, and, therefore, will contribute to the improvement of the mechanical properties of the self-reinforced powder material due to the effects of both solid-solution strengthening by interstitial atoms and the precipitation strengthening by the carbide phase particles.