Review on high-entropy alloy reinforced aluminum matrix composites fabricated by laser powder bed fusion

This review provides a systematic overview of the current research status and future prospects for preparing high-entropy alloy (HEA)-reinforced aluminum matrix composites (AMCs) using laser powder bed fusion (LPBF) additive manufacturing technology. Compared to conventional aluminum alloys, Al–Si-based alloys (particularly AlSi10Mg) emerge as the optimal choice for LPBF due to their narrow solidification range and excellent formability. As novel reinforcements, HEAs exhibit high strength, good plasticity, and superior deformation capability, significantly enhancing the overall performance of composites. HEAs exert grain refinement strengthening, solid solution strengthening, and dispersion strengthening effects on the Al matrix. Compared to traditional ceramic particle reinforcements, HEAs efficiently transmit loads and resist interfacial cracking, substantially reducing plasticity loss while enhancing strength. Research indicates that in HEA-reinforced AlSi10Mg composites fabricated via LPBF, HEAs exhibit excellent bonding with the aluminum matrix. A transition layer and fine secondary phases form at the interface, contributing to grain refinement. An appropriate HEA addition markedly increases the composite strength with only a slight decrease in elongation. Furthermore, synergistic effects between HEAs and other reinforcements (e.g., TiB₂) can further improve melt pool stability and optimize the material’s overall performance. Although research on LPBF-fabricated HEA-reinforced AMCs remains in its infancy, it has demonstrated immense application potential. Future studies should delve deeper into the reinforcement mechanisms of HEAs in AMCs, integrating structural design and process optimization to fully leverage the advantages of additive manufacturing and advance this technology toward industrial application.