Research Projects

Designing materials capable of withstanding high-impact forces with superior energy absorption is crucial for defense and automotive applications. Current solutions—high-strength steels, ceramics, and conventional alloys—have notable limitations. Steels contribute to excessive weight, ceramics exhibit brittleness under dynamic loads, and traditional alloys often lack adequate plastic deformation. A novel approach is essential to address these performance gaps in critical safety systems. High Entropy Alloys (HEAs), defined by their multi-principal element compositions in near-equiatomic ratios, offer remarkable mechanical characteristics. Their solid-solution phases, lattice distortions, and sluggish diffusion effects contribute to high strength, wear resistance, and thermal stability. Despite this potential, limited research exists on tailoring HEAs for energy absorption. Moreover, processing complexities and the absence of real-world validation restrict their broader application. The proposed study aims to develop a customized HEA composition optimized specifically for impact resistance. The research adopts Laser Directed Energy Deposition (Laser DED), a precision-based additive manufacturing method capable of controlling alloy composition and microstructure. Although Laser DED has shown promise, its use in fabricating HEAs with high energy absorption remains underexplored. The research plan is structured into four stages. Initially, a meta-analysis will extract and compare existing data on HEA compositions, emphasizing properties related to strain-rate sensitivity and impact response. This will be followed by the fabrication of a short-listed composition using the Laser DED technique. Process parameters such as laser power, scanning speed, and powder feed rate will be systematically optimized. Subsequently, microstructural and mechanical characterization will be conducted using XRD, SEM, and EDS, alongside tests for hardness, compressive strength, and wear behavior. Finally, energy absorption performance will be validated through Charpy impact testing, drop-weight assessments, and Split Hopkinson Pressure Bar (SHPB) experiments. The hypothesis guiding this research is that a HEA designed through meta-analysis and fabricated via Laser DED can exhibit enhanced energy absorption, superior to conventional alloys. Controlled processing is expected to yield uniform microstructures with optimized phase formation, contributing to improved strength–ductility synergy. Outcomes from this investigation are anticipated to enhance understanding of structure–property–processing relationships in HEAs by publishing articles and filing patents. Insights into deformation mechanisms and dynamic behavior will be valuable for future alloy design. On the application side, the results can enable the development of light, durable materials for use in protective armor, crash structures, and high-impact industrial components.

High Entropy Alloys, Energy Absorption, Laser DED, Additive Manufacturing.