Synergy of cellular architecture and dual-precipitation on the high-cycle fatigue mechanisms of an additively manufactured high-entropy alloy: Al0.2Co1.5CrFeNi1.5Ti0.3

Poresh Kumar; Tu Ngoc Lam; Jing Syuan Lai; Lia Amalia; Po heng Chou; An Chou Yeh; Winson C.H. Kuo; Peter K. Liaw; Ching Yu Chiang; Wan Zhen Hsieh; Ke An; Yan Chen; Dunji Yu; Sudhanshu Shekhar Singh; E. Wen Huang

doi:10.1016/j.mtla.2026.102757

Synergy of cellular architecture and dual-precipitation on the high-cycle fatigue mechanisms of an additively manufactured high-entropy alloy: Al_0.2Co_1.5CrFeNi_1.5Ti_0.3

Poresh Kumar
, Tu Ngoc Lam
, Jing Syuan Lai
, Lia Amalia
, Po heng Chou
, An Chou Yeh
, Winson C.H. Kuo
, Peter K. Liaw
, Ching Yu Chiang
, Wan Zhen Hsieh
, Ke An
, Yan Chen
, Dunji Yu
, Sudhanshu Shekhar Singh
, E. Wen Huang

Materials Engineering

Research output: Contribution to journal › Article › peer-review

1 Scopus citations

Abstract

Multi-principal element alloys (MPEAs) have emerged as a promising class of materials due to their attractive physical and mechanical properties. Recent studies have demonstrated that these alloys can achieve exceptional strength-ductility combinations, especially when strengthened through precipitation engineering. With the increasing use of additive manufacturing (AM), further improvements have been realized through the formation of hierarchical microstructures. However, fatigue behavior is critical for structural applications, remains less explored. In this work, we investigate tensile and high cycle fatigue (HCF) performance, respectively, of a dual-precipitation-strengthened Al_0.2Co_1.5CrFeNi_1.5Ti_0.3 high-entropy alloy (HEA) fabricated by selective laser melting (SLM). Comprehensive characterization was performed to examine the interplay between AM-induced microstructural features and precipitation behavior, and their combined influence on fatigue mechanisms. The alloy exhibits a notable endurance strength of ∼0.4 - 0.5 times its ultimate tensile strength (UTS), which is competitive with or superior to many AM structural alloys. The coherent L1₂ precipitates contribute significantly to strengthening under both monotonic and cyclic loading, while the L2₁ precipitates also contributed in resistance to fatigue crack propagation.

Original language	English
Article number	102757
Journal	Materialia
Volume	46
DOIs	https://doi.org/10.1016/j.mtla.2026.102757
State	Published - May 2026

Funding

The authors acknowledge the support received from Department of Materials Science and Engineering as well as Advanced Center for Materials Science at the Indian Institute of Technology Kanpur. The authors are grateful for the support of the National Science and Technology Council (NSTC) under Grants NSTC 114-2923-E-A49-003-MY3 , 114-2221-E-A49-002 -, and 114-2811-E-A49-527 . PK thanks the support from Fellowship for Academic and Research Excellence (FARE), The Indian Institute of Technology Kanpur (IITK), India. EWH appreciates the travel support from the National Synchrotron Radiation Research Center (NSRRC) - Neutron Travel Program. This work was financially supported by the “High Entropy Materials Center” from The Featured Areas Research Center Program within the framework of the Higher Education Sprout Project by the Ministry of Education (MOE) in Taiwan. This work is supported by NSTC T-Star Center Project: Future Semiconductor Technology Research Center under NSTC 114-2634-F-A49-001 -. The current work is supported by Center for Advanced Semiconductor Technology Research under Higher Education Sprout Project of Ministry of Education, Taiwan. P.K.L. very much appreciates the support from the National Science Foundation ( DMR-1611180 , 1809640 , and 2226508 ) and the US Army Research Office ( FA9550-23-1-0503 , W911NF-13-1-0438 , and W911NF-19-2 0049 ). The authors gratefully acknowledge the use of “High-performance low temperature and multi-function X-ray diffractometer” belonging to the Core Facility Center of the National Yang Ming Chiao Tung University. PK acknowledges IIT Kanpur and ICST-NYCU Taiwan for financial support during the period of investigation. A portion of the current research used resources at the Spallation Neutron Source, a DOE Office of Science User Facility operated by the Oak Ridge National Laboratory. Additional TEM work was performed, in part, at the Center for Integrated Nanotechnologies, an Office of Science User Facility operated for the U.S. Department of Energy (DOE) Office of Science. Los Alamos National Laboratory, an affirmative action equal opportunity employer, is managed by Triad National Security, LLC for the U.S. Department of Energy’s NNSA, under contract 89233218CNA000001.

Keywords

Additive manufacturing
Fatigue resistance
High cycle fatigue
High-entropy alloys
Precipitation strengthening
Tensile property

Access to Document

10.1016/j.mtla.2026.102757

Cite this

Kumar, P., Lam, T. N., Lai, J. S., Amalia, L., Chou, P. H., Yeh, A. C., Kuo, W. C. H., Liaw, P. K., Chiang, C. Y., Hsieh, W. Z., An, K., Chen, Y., Yu, D., Shekhar Singh, S., & Huang, E. W. (2026). Synergy of cellular architecture and dual-precipitation on the high-cycle fatigue mechanisms of an additively manufactured high-entropy alloy: Al_0.2Co_1.5CrFeNi_1.5Ti_0.3. Materialia, 46, Article 102757. https://doi.org/10.1016/j.mtla.2026.102757

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title = "Synergy of cellular architecture and dual-precipitation on the high-cycle fatigue mechanisms of an additively manufactured high-entropy alloy: Al0.2Co1.5CrFeNi1.5Ti0.3",

abstract = "Multi-principal element alloys (MPEAs) have emerged as a promising class of materials due to their attractive physical and mechanical properties. Recent studies have demonstrated that these alloys can achieve exceptional strength-ductility combinations, especially when strengthened through precipitation engineering. With the increasing use of additive manufacturing (AM), further improvements have been realized through the formation of hierarchical microstructures. However, fatigue behavior is critical for structural applications, remains less explored. In this work, we investigate tensile and high cycle fatigue (HCF) performance, respectively, of a dual-precipitation-strengthened Al0.2Co1.5CrFeNi1.5Ti0.3 high-entropy alloy (HEA) fabricated by selective laser melting (SLM). Comprehensive characterization was performed to examine the interplay between AM-induced microstructural features and precipitation behavior, and their combined influence on fatigue mechanisms. The alloy exhibits a notable endurance strength of ∼0.4 - 0.5 times its ultimate tensile strength (UTS), which is competitive with or superior to many AM structural alloys. The coherent L12 precipitates contribute significantly to strengthening under both monotonic and cyclic loading, while the L21 precipitates also contributed in resistance to fatigue crack propagation.",

keywords = "Additive manufacturing, Fatigue resistance, High cycle fatigue, High-entropy alloys, Precipitation strengthening, Tensile property",

author = "Poresh Kumar and Lam, \{Tu Ngoc\} and Lai, \{Jing Syuan\} and Lia Amalia and Chou, \{Po heng\} and Yeh, \{An Chou\} and Kuo, \{Winson C.H.\} and Liaw, \{Peter K.\} and Chiang, \{Ching Yu\} and Hsieh, \{Wan Zhen\} and Ke An and Yan Chen and Dunji Yu and \{Shekhar Singh\}, Sudhanshu and Huang, \{E. Wen\}",

note = "Publisher Copyright: {\textcopyright} 2026 Acta Materialia Inc.",

year = "2026",

month = may,

doi = "10.1016/j.mtla.2026.102757",

language = "English",

volume = "46",

journal = "Materialia",

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Kumar, P, Lam, TN, Lai, JS, Amalia, L, Chou, PH, Yeh, AC, Kuo, WCH, Liaw, PK, Chiang, CY, Hsieh, WZ, An, K , Chen, Y , Yu, D, Shekhar Singh, S & Huang, EW 2026, 'Synergy of cellular architecture and dual-precipitation on the high-cycle fatigue mechanisms of an additively manufactured high-entropy alloy: Al_0.2Co_1.5CrFeNi_1.5Ti_0.3', Materialia, vol. 46, 102757. https://doi.org/10.1016/j.mtla.2026.102757

TY - JOUR

T1 - Synergy of cellular architecture and dual-precipitation on the high-cycle fatigue mechanisms of an additively manufactured high-entropy alloy

T2 - Al0.2Co1.5CrFeNi1.5Ti0.3

AU - Kumar, Poresh

AU - Lam, Tu Ngoc

AU - Lai, Jing Syuan

AU - Amalia, Lia

AU - Chou, Po heng

AU - Yeh, An Chou

AU - Kuo, Winson C.H.

AU - Liaw, Peter K.

AU - Chiang, Ching Yu

AU - Hsieh, Wan Zhen

AU - An, Ke

AU - Chen, Yan

AU - Yu, Dunji

AU - Shekhar Singh, Sudhanshu

AU - Huang, E. Wen

PY - 2026/5

Y1 - 2026/5

N2 - Multi-principal element alloys (MPEAs) have emerged as a promising class of materials due to their attractive physical and mechanical properties. Recent studies have demonstrated that these alloys can achieve exceptional strength-ductility combinations, especially when strengthened through precipitation engineering. With the increasing use of additive manufacturing (AM), further improvements have been realized through the formation of hierarchical microstructures. However, fatigue behavior is critical for structural applications, remains less explored. In this work, we investigate tensile and high cycle fatigue (HCF) performance, respectively, of a dual-precipitation-strengthened Al0.2Co1.5CrFeNi1.5Ti0.3 high-entropy alloy (HEA) fabricated by selective laser melting (SLM). Comprehensive characterization was performed to examine the interplay between AM-induced microstructural features and precipitation behavior, and their combined influence on fatigue mechanisms. The alloy exhibits a notable endurance strength of ∼0.4 - 0.5 times its ultimate tensile strength (UTS), which is competitive with or superior to many AM structural alloys. The coherent L12 precipitates contribute significantly to strengthening under both monotonic and cyclic loading, while the L21 precipitates also contributed in resistance to fatigue crack propagation.

AB - Multi-principal element alloys (MPEAs) have emerged as a promising class of materials due to their attractive physical and mechanical properties. Recent studies have demonstrated that these alloys can achieve exceptional strength-ductility combinations, especially when strengthened through precipitation engineering. With the increasing use of additive manufacturing (AM), further improvements have been realized through the formation of hierarchical microstructures. However, fatigue behavior is critical for structural applications, remains less explored. In this work, we investigate tensile and high cycle fatigue (HCF) performance, respectively, of a dual-precipitation-strengthened Al0.2Co1.5CrFeNi1.5Ti0.3 high-entropy alloy (HEA) fabricated by selective laser melting (SLM). Comprehensive characterization was performed to examine the interplay between AM-induced microstructural features and precipitation behavior, and their combined influence on fatigue mechanisms. The alloy exhibits a notable endurance strength of ∼0.4 - 0.5 times its ultimate tensile strength (UTS), which is competitive with or superior to many AM structural alloys. The coherent L12 precipitates contribute significantly to strengthening under both monotonic and cyclic loading, while the L21 precipitates also contributed in resistance to fatigue crack propagation.

KW - Additive manufacturing

KW - Fatigue resistance

KW - High cycle fatigue

KW - High-entropy alloys

KW - Precipitation strengthening

KW - Tensile property

UR - https://www.scopus.com/pages/publications/105037325535

U2 - 10.1016/j.mtla.2026.102757

DO - 10.1016/j.mtla.2026.102757

M3 - Article

AN - SCOPUS:105037325535

SN - 2589-1529

VL - 46

JO - Materialia

JF - Materialia

M1 - 102757

ER -