Processing–Microstructure–Property Relationships in a Cu-Rich FeCrMnNiAl High-Entropy Alloy Fabricated by Laser and Electron Beam Powder Bed Fusion

A Cu-containing FeCrMnNiAl multi-principal element alloy was processed by laser-based and electron beam-based powder bed fusion (PBF-LB/M and PBF-EB/M) to investigate processing-microstructure-property relationships. In focus were alloy variants with a relatively high Cu content. Two PBF-LB/M scan strategies, employing a Gaussian beam with and without a re-scan with a laser featuring a flat-top profile, were compared to PBF-EB/M processing, followed by heat-treatments between 300 °C and 1000 °C. The phase constitution, elemental partitioning and grain boundary characteristics were analyzed by X-ray diffraction, electron backscatter diffraction and energy-dispersive X-ray spectroscopy. Mechanical behavior was assessed by hardness and tensile testing. Both manufacturing routes promoted the evolution of stable multi-phase microstructures composed of face-centered-cubic (FCC)- and body-centered-cubic (BCC)-type phases across all heat-treatment conditions. PBF-LB/M processing resulted in finer, dendritic microstructures and suppressed formation of a Cu-rich FCC phase due to higher cooling rates, whereas PBF-EB/M promoted the evolution of Cu-rich FCC segregates and equiaxed grain morphologies. Heat-treatment above 700 °C led to recrystallization, accompanied by an increase of the FCC phase fraction, grain coarsening, and recovery. At lower heat-treatment temperatures, the changes in microstructure are different. Here, it is assumed that small, non-clustered Cu-rich precipitates formed at the grain and sub-grain boundaries, although this assumption is only based on the assessment of the mechanical properties. The size of these precipitates is below the resolution limit of the techniques applied for analysis in the present work. Additional structures seen within the Cu-rich areas of PBF-EB/M-manufactured samples treated at lower temperatures also seem to have an influence on the hardness and yield strength. All of the conditions investigated exhibited pronounced brittleness, limiting reliable tensile property evaluation and indicating the need for further optimization of processing strategies and microstructural control for high-Cu-fraction-containing multi-principal element alloys.