Advances in High-Entropy Alloy Research: Unraveling Fabrication Techniques, Microstructural Transformations, and Mechanical Properties

Abstract High-entropy alloys (HEAs) have emerged as promising materials with exceptional mechanical properties, thus, making them suitable for demanding applications that require high strength and toughness. This review highlights the latest advancements in HEA research, focusing on processing techniques, microstructural evolution, and mechanical properties and behavior techniques. The unique HEA composition comprising four or more principal elements in almost equiatomic ratios produces high configurational entropy, which stabilizes distinct solid solution phases. This stabilization leads to microstructures distinguished by disorder and set of defect types, generating superior mechanical properties. For several years, substantial advancement has been achieved in HEA processing routes, from traditional casting and powder metallurgy to state-of-the-art methods such as additive manufacturing and severe plastic deformation. These processes, combined with a developing understanding of microstructural evolution and phase transformations, are broadening the potential application of HEAs in aerospace, energy, and automotive. As the field progresses, the implications of these findings are shaping future research directions and expanding the potential applications of HEAs in various industries. This review underscores the current challenges in tailoring the microstructure of HEAs and optimizing their mechanical functionality, laying the foundation for future innovations and practical use.