Microstructure and mechanical properties of mechanically-alloyed CoCrFeNi high-entropy alloys using low ball-to-powder ratio

High-entropy alloys are extensively studied due to their very promising properties. However manufacturing methods currently used to prepare HEAs are complicated, costly, and likely non-industrially scalable processes. This limits their evolution and poses questions regarding the material's applicability in the future. Considering the abovementioned point, we developed a novel methodology for efficient HEA production using a low ball-to-powder ratio (BPR). Using different milling times, we manufactured four HEA powder precursors using a BPR of 5:1, which were later sintered via the Spark Plasma Sintering technique and heat treated. Microstructural characterisation was performed by optical microscopy, Scanning Electron Microscopy equipped with EDS and EBSD detectors, and X-ray diffraction. Mechanical properties were measured using nano and microhardness techniques. In this work, we follow the structural evolution of the material and connect it with the strengthening effect as a function of milling time. Furthermore, we discuss the impact of different sintering and annealing conditions, proving that HEAs characterised by high mechanical properties may be manufactured using low BPR.