高熵合金粉体研究进展-中国粉体技术

高熵合金粉体研究进展
Research progress on high⁃entropy alloy powders

张卫东^1，2，张熙辰¹ ，曹远奎³，彭飞¹ ，朱宝辉^4，5 ，李小平⁴，吴正刚¹

1. 湖南大学材料科学与工程学院，湖南长沙 410082；

2. 湖大粤港澳大湾区创新研究院（广州增城），广东广州 511300；

3. 中南大学粉末冶金国家重点实验室，湖南长沙 410083；

4. 西北稀有金属材料研究院宁夏有限公司稀有金属特种材料国家重点实验室，宁夏石嘴山 753000；

5. 宁夏中色金航钛业有限公司，宁夏石嘴山753000

引用格式：

张卫东，张熙辰，曹远奎，等. 高熵合金粉体研究进展［J］. 中国粉体技术，2025，31（3）：1-16.

ZHANG Weidong， ZHANG Xichen， CAO Yuankui， et al. Research progress on high-entropy alloy powders［J］. China Powder Science and Technology，2025，31（3）：1−16.

收稿日期：2024-09-04，修回日期：2025-03-05，上线日期：2025-03-26。

基金项目：中国科学技术协会青年人才托举工程，编号：YESS20220503；国家自然科学基金项目，编号：52474389；西北稀有金属材料研究院宁夏有限公司稀有金属特种材料国家重点实验室开放课题基金，编号：SKL2022K002。

第一作者简介：张卫东（1991—），男，副教授，博士，硕士生导师，第八届中国科协青年人才托举工程计划获得者，研究方向为粉末冶金金属结构材料。E-mail：weidongzhang@hnu. edu. cn。

通信作者简介：吴正刚（1987—），男，教授，博士，博士生导师，国家高层次青年人才项目获得者，研究方向为高熵合金与陶瓷材料。Email：zwu@hnu. edu. cn。

摘要：【目的】为推动高熵合金粉体领域的创新发展提供参考，对高熵合金的概念与分类、制备技术与应用现状进行总结和阐述。【研究现状】综述由4、5种或者更多金属元素以近等原子比例构成的混合熵高于1. 6 R的高熵合金，也被称为多主元合金或复杂组元合金；与传统合金相比，高熵合金具有诸多性能优势，例如，优异的高、低温力学性能，良好的耐腐蚀性能和抗辐照性能等；概括高熵合金粉体制备技术，包括机械合金化、雾化法（水雾化、气雾化、等离子旋转电极雾化法）、射频等离子球化法、等离子电弧法、化学还原法等；总结高熵合金粉体在粉末冶金块体材料、增材制造、涂层（薄膜）、催化、储氢等领域的应用。【结论与展望】认为经过近10 a的发展，高熵合金粉体的制备和应用研究均取得了较好的进展，并已初步探索高熵合金粉体的市场化生产与应用的可行性；提出未来研究应聚焦于适用于难熔高熵合金粉体制备的新方法、新技术，批量化制备，性能优化与机制等问题。

关键词：高熵合金粉体；雾化；等离子球化；增材制造；催化；储氢

Abstract

Significance High-entropy alloys （HEAs）， as a new complex multi-principal element alloys， exhibit unique design and exceptional physical and chemical properties， showing great potential in structural materials， functional materials， and biomedical applications. This study analyzes the advantages， disadvantages， and industrial prospects of existing preparation methods for HEA powders， offering insights for the development of new preparation methods and large-scale production tailored to different application scenarios.

Progress HEA powder preparation techniques include mechanical alloying （MA）， atomization， radio frequency plasma spheroidization （RFPS）， plasma arc discharge （PAD）， and chemical reduction （CR）. MA can produce single-phase face-centered cubic （FCC） or body-centered cubic （BCC） HEA powders， as well as powders with complex phase structures. Gasatomization produces powders with high purity， low oxygen content， uniform composition， excellent sphericity， and minimal impurities， making it suitable for thermal spraying， refractory high-entropy alloy （RHEA） production， and injection molding，with broad application prospects. Water atomization is cost-effective， efficient， and suitable for large-scale production， though it produces powders with inferior sphericity and higher impurity levels compared to gas atomization. Plasma rotating electrode process （PREP） excels in producing spherical metal powders with ultra-low gap element content， featuring high sphericity，minimal satellite particles， and negligible hollow powders， though it yields powders with larger particle sizes and low fine powder production rates. RFPS， characterized by high temperature and enthalpy （≥8000 °C）， large plasma torches， and controllable plasma atmospheres， has significant advantages in preparing spherical RHEA powders with high sphericity， minimal internal defects， controllable particle size， good flowability， and uniform composition. However， this method requires pre-alloyed powders prepared via MA or spray drying， resulting in longer production cycles and lower efficiency. PAD and CR are primarily used to produce high-entropy alloy nanoparticles （HEA-NPs）， yielding powders with fine， uniform particle sizes， high purity，large specific surface areas， and excellent catalytic stability. HEA powders are mainly applied in structural components through powder metallurgy， additive manufacturing， coatings， and films， as well as in catalysis and hydrogen storage. In structural applications， HEA powders serve as raw materials， while in catalysis and hydrogen storage， they are used directly as the final materials. HEA powders are commonly used in powder metallurgy to prepare structural components. These powders， typically elemental mixed powders or pre-alloyed powders， are processed through ball milling/mixing， pressing， sintering， and subsequent treatments to produce bulk HEA materials. The high uniformity of powder materials in powder metallurgy effectively mitigates issues such as compositional segregation， dendrite formation， and multiphase precipitation， which are common in traditional casting， resulting in uniform HEA solid solution materials with excellent comprehensive properties. Additive manufacturing of HEAs has advanced rapidly， although early research was constrained by challenges in spherical powder production. As a result， the raw materials for additive manufacturing of HEAs primarily consisted of mixed elemental powders. Since 2015， gasatomized HEA powders have been successfully used in additive manufacturing， enabling the production of multi-principal element HEA systems through laser additive technologies. HEA coatings and films exhibit properties similar to bulk HEAs， finding applications in high-temperature， anti-corrosion， and wear-resistant environments. These powders are used to prepare hard protective coatings for tools and molds. They can also be used to produce thin-film materials with excellent toughness， high fatigue resistance， and electrical resistivity， suitable for flexible electronic devices and micro-electromechanical systems. HEA-NPs offer unique advantages in electrocatalysis， including abundant active sites， high flexibility， strong cascade reactions， and optimized adsorption site electron structures. Additionally， HEA powders are promising hydrogen storage materials due to the significant lattice distortion of BCC HEAs and the varying atomic radii， which create large interstitial spaces and enhance matrix-hydrogen bonding. The multi-principal-element characteristic further enhances the binding energy between the matrix and hydrogen. The selection of HEA powder preparation techniques should prioritize the required powder properties and process characteristics for specific applications， while considering economic viability， environmental impact， and scalability.

Conclusions and Prospects Over the past decade， significant progress has been made in the preparation and application of HEA powders， with preliminary explorations into market-oriented production and application feasibility. However， many challenges remain in the field of HEA powders， and future research should focus on the following key areas. The development of HEA powders still relies on traditional metal powder preparation theories. Given the complex compositions and diverse elements of HEAs， new theories tailored to different HEA systems should be developed. Existing preparation techniques primarily stem from conventional metal powder processes， which face significant challenges in producing RHEA powders with uniform compositions and microstructures. Future research should aim to combine new theories with innovative methods and technologies for HEA powder preparation. Systematic studies on the large-scale production of HEA powders are limited. Future efforts should enhance research in this area， focusing on improving existing scalable preparation techniques， developing new processes， and addressing cost control and environmental concerns to accelerate market-oriented production. While HEA powder applications in structural materials have been widely studied， research into their use in functional materials， such as energy storage， magnetism， and catalysis， remains in its initial stage. Given their immense potential in these fields， functional HEA powders are expected to become a research focus in both fundamental theory and engineering applications， especially in areas such as composition design， ultra-fine powder preparation， performance optimization， and mechanisms to drive foundational and engineering applications of functional HEA powders.

Keywords：high-entropy alloy powder； atomization； plasma spheroidization； additive manufacturing； catalysis； hydrogen storage

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高熵合金粉体研究进展Research progress on high⁃entropy alloy powders

高熵合金粉体研究进展
Research progress on high⁃entropy alloy powders