Synthesis, microstructural investigation and compaction behavior of Al0.3CrFeNiCo0.3Si0.4 nanocrystalline high entropy alloy

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This research article focused on developing Al0.3CrFeNiCo0.3Si0.4 nanocrystalline high-entropy alloy (HEA) by mechanical alloying. The initial powders mixture was ball milled for 1 hr (HEA-1 h), 5 hr (HEA-5 h), 15 hr (HEA-15 h) and 25 hr (HEA-25 h) at ball to powder mass ratio (BPR) of 15:1 and a speed of 300 rpm. The mechanical alloying time was varied from 1 to 25 hr to ensure the nanocrystalline nature and attainment of steady state in HEA powders. The structure of the developed HEAs was characterized by means of X-ray diffraction (XRD), Laser particle size analyzer (LPSA), and various electron microscopes (TEM and FEGSEM with EDS). HEA-25hr sample exhibited the crystallite size of 13.8 nm with lattice strain of 0.67% obtained from XRD which matched the result by TEM. The formation of a solid solution (SS) with a uniform elemental dispersion was observed with a major BCC stable structure and a minor FCC structure in HEA-25 h sample. The HEA-25 h sample revealed an average particle size of 386.2 nm (89.8% peak intensity) with Polydispersity Index (PDI) value of 0.364 which confirmed the uniform distribution of particles over a narrow range of particle size. The synthesized powders were consolidated to green compacts with a loading rate of 1 mm/min at different compaction pressures (25, 50, 75, 100, 150, 200, 400, 600, 800, 1000, and 1100 MPa) for examining the powder particles packing. Several compaction models (both linear and non-linear) were discussed to establish the density-pressure relationship of developed HEAs. The results revealed that the milling time has influenced the relative density. HEA-1 h sample was exhibited the relative density of 0.76 whereas HEA-25 h sample was produced the relative density of 0.6 indicating more strength and more amount of strain hardening occurs in MAed HEA-25 sample in addition to the entropy effect for the same composition.

Original languageEnglish
Pages (from-to)398-412
Number of pages15
JournalAdvanced Powder Technology
Issue number2
StatePublished - Feb 2021


  • AlCrFeNiCoSi high entropy alloy
  • Compaction behavior
  • Mechanical alloying
  • Microstructure investigation


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