Advances in Additively Manufactured Multi-Principal Element Alloys for Turbine Blades in Next Generation Jet Engines

In the 21st century, the desire for improved fuel efficiency of engines, lower fuel prices, and the need to reduce greenhouse gas emissions such as CO2 and NOx are leading the aviation industry to seek hybrid-electric jet engines for commercial aircraft. These aircraft will have greater maintenance challenges due to additional components requiring more reliable materials for the engine’s parts, such as turbine blades. Turbine blades must be composed of materials that have enhanced fatigue performance. Resistance to dynamic loads and high strength will be needed to ensure modern gas turbine blades are as reliable as possible. This review paper examines hybrid-electric engine turbine blades and subsequently introduces additive manufacturing (AM) and multi-principal element alloys (MPEAs) with a focus on laser powder bed fusion (LPBF), high-entropy alloys (HEAs), and medium-entropy alloys (MEAs). The tensile properties of LPBF HEAs range from 5 to 47% elongation and a UTS of 572–1640 MPa, while LPBF MEAs range from 8 to 73.9% and a UTS of 573–1382 MPa. This study focused on dynamic and fatigue properties while acknowledging gaps in high-temperature testing. The combination of mechanical properties with the ability to control internal geometry makes these AM alloys an attractive option for the next generation of gas turbine blades.