DONG Fuyu¹， LIU Feng¹， SHEN Xiangyang¹， LIU Chao¹， TIAN Yu²， SU Xin¹， REN Guangtao¹， ZHOU Guishen¹， ZHANG Yue¹， CHENG Jun³

1.School of Materials Science and Engineering， Shenyang University of Technology， Shenyang 110000， China； 

2.Department of Intelligent Manufacturing， Liaohe Petroleum Vocational and Technical College， Panjin 124000 China；

3.Shanxi Key Laboratory of Biomedical Metal Materials， Northwest Institute for Non-ferrous Metal Research， Xi’an 710016， China

Abstract

Significance　High-entropy alloys （HEAs） are mainly prepared using traditional melting and casting methods， which often result in issues such as severe component segregation， coarse microstructures， and internal shrinkage defects. These limitations and constraints on size and shape hinder their broader engineering applications. However， with the rapid development of science and technology， advanced near-net-shape forming technologies， such as 3D printing and powder metallurgy， have been gradually applied to HEA powder preparation. In recent years， HEA powders have gained significant attention as raw materials for the preparation of bulk components， coatings， films， and other functional materials. Despite this growing interest， comprehensive studies on HEA powders， especially nano-sized powders， remain rare. To enhance our understanding of HEA powders， this paper comprehensively examines their preparation processes， curing methods， and functional applications， providing a reference for future development and theoretical research on HEA powder preparation.

Progress　This review systematically summarizes recent advancements in HEA powder preparation techniques， including mechanical alloying（ MA）， gas atomization， plasma rotating electrode atomization， carbothermal shock（ CTS）， pyrolysis， electric shock， scanning probe lithography， plasma arc， DC arc evaporation， and chemical reduction. Each method is evaluated for its advantages and limitations. The solidification processes of HEA powders， such as sintering， coating， and additive manufacturing， are discussed. The functional applications of HEA powders are also investigated， including hydrogen storage， medical and bioengineering， catalysts， and electromagnetic shielding. For instance， their excellent mechanical properties and biocompatibility make them ideal for orthopedic implants and dental treatment materials. In environmental and energy applications，HEA powders can be efficient catalysts. They can also be used as electromagnetic shielding materials such as electromagnetic shielding wall panels and electromagnetic isolation rooms.

Conclusions and Prospects　Although significant achievements have been made in the design and preparation of HEA powders，considerable challenges remain. MA and atomization are currently the main methods for preparing HEA powders， but further improvements in efficiency and powder quality are needed. Future research should focus on addressing fundamental issues in powder preparation and developing innovative preparation methods. Their structural stability， mechanical properties， and functional performance in energy storage， magnetism， and catalysis need to be further studied. Additive manufacturing， with its ability to create unique dislocation structures and microstructures， holds great potential in developing high-performance HEA materials. Through material genetic engineering， high-throughput powder metallurgy techniques can accelerate the screening of HEA components， shortening the development cycle of alloys. In addition， the flexibility of powder metallurgy enables the design of  heterogeneous HEA materials such as composite， layered， and gradient structures， which have potential applications in aerospace， biomedical engineering， and other fields， promoting further development of HEA technologies.

Keywords：high-entropy alloy； atomization； rotating electrode； solidification process； carbothermal； electric shock

Get Citation: DONG Fuyu， LIU Feng， SHEN Xiangyang， et al. Development status of high-entropy alloy powder preparation techniques and applications［J］. China Powder Science and Technology， 2025， 31（6）： 1−15.

Received: 2024-01-10 .Revised: 2024-03-06 ,Online: 2025-05-29

Funding Project: 国家自然科学基金项目，编号：52271249； 辽宁省自然科学基金联合项目，编号：2023JH2/101700276； 西北工业大学凝固技术国家重点实验室开放课题：编号：SKLSP202415；西安英才计划项目，编号：XAYC240016。

First Author: 董福宇（1984—），男，教授，博士，博士生导师，辽宁省“百千万人才工程”万层次人才，研究方向为新型非晶合金及形成规律、高熵合金形变强化等。E-mail：dongfuyu@sut. edu. cn。

Corresponding Author: 程军（1985—），男，高级工程师，博士，硕士生导师，研究方向为稀有金属材料制备与加工。E-mail：chengjun_851118@126. com。

DOI：10.13732/j.issn.1008-5548.2025.06.007

CLC No: TB4               Type Code: A

Serial No:1008-5548（2025）06-0001-15