Multi-objective grey wolf optimization of selective laser melting process parameters for the fabrication of Al0.2CuFeMnNi high entropy alloy and evaluation of mechanical, tribological and corrosion behaviour

IF 4.8 2区材料科学 Q2 CHEMISTRY, PHYSICAL

Intermetallics Pub Date : 2025-08-27 DOI:10.1016/j.intermet.2025.108968

Hareharen K, Panneerselvam T

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Abstract

Al_0.2CuFeMnNi high entropy alloy (HEA) has emerged as a promising material for structural and functional applications; however, its performance is strongly influenced by processing conditions during selective laser melting (SLM). This study focuses on enhancing the performance and surface quality, such as relative density (RD), Vickers Micro-hardness (VMH), and surface roughness (SR_a), by optimizing SLM parameters, laser power (P_l), scanning speed (V_s), and hatch spacing (H_s). A hybrid framework integrating random forest regression (RF-Reg) and multi-objective grey wolf optimization (MO-GWO) was developed to predict and optimize the process parameters. MO-GWO optimization produced RD of 98.63 %, VMH of 236.60 HV, and SR_a of 23.42 μm with P_l of 197.93 W, V_s of 753.40 mm/s, and H_s of 0.05 mm. The reliability of the optimization was confirmed by experimental validation. For RD, VMH, and SR_a, the error percentages among the outcomes from the experiment and the MO-GWO optimization model are 0.23 %, 1.75 %, and 6.30 %, respectively. Tensile testing revealed excellent mechanical performance with the yield strength of 525 MPa and an ultimate tensile strength of 649 MPa. Dry sliding wear analysis showed an increasing wear rate from 3.6464 x 10⁻⁴ at 20 N to 8.0439 x 10⁻⁴ at 40 N with decreasing coefficient of friction. Electrochemical analysis shows excellent corrosion resistance with corrosion potential, current density and polarization resistance of −430.784 mV, 12.911 μA/cm², and 3947.6 Ω cm² respectively. These results validate the effectiveness of the proposed optimization approach in enhancing the quality and performance of SLM-fabricated Al_0.2CuFeMnNi HEA.

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Al0.2CuFeMnNi高熵合金选择性激光熔化工艺参数的多目标灰狼优化及力学、摩擦学和腐蚀性能评价

Al0.2CuFeMnNi高熵合金（HEA）在结构和功能方面具有广阔的应用前景；然而，在选择性激光熔化（SLM）过程中，其性能受到加工条件的强烈影响。本研究的重点是通过优化SLM参数、激光功率（Pl）、扫描速度（Vs）和舱口间距（Hs）来提高性能和表面质量，如相对密度（RD）、维氏显微硬度（VMH）和表面粗糙度（SRa）。建立了随机森林回归（RF-Reg）和多目标灰狼优化（MO-GWO）相结合的混合框架，对工艺参数进行预测和优化。MO-GWO优化后的RD为98.63%，VMH为236.60 HV， SRa为23.42 μm， Pl为197.93 W， Vs为753.40 mm/s， Hs为0.05 mm。实验验证了优化的可靠性。对于RD、VMH和SRa，实验结果与MO-GWO优化模型的误差百分比分别为0.23%、1.75%和6.30%。拉伸试验表明，该材料的屈服强度为525 MPa，极限抗拉强度为649 MPa，力学性能优良。干滑动磨损分析表明，随着摩擦系数的减小，磨损率从20 N时的3.6464 x 10−4增加到40 N时的8.0439 x 10−4。电化学分析表明，腐蚀电位、电流密度和极化电阻分别为- 430.784 mV、12.911 μA/cm2和3947.6 Ω cm2，具有良好的耐腐蚀性能。这些结果验证了所提出的优化方法在提高slm制备的Al0.2CuFeMnNi HEA的质量和性能方面的有效性。

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来源期刊

Intermetallics 工程技术-材料科学：综合

CiteScore

7.80

自引率

9.10%

发文量

291

审稿时长

37 days

期刊介绍： This journal is a platform for publishing innovative research and overviews for advancing our understanding of the structure, property, and functionality of complex metallic alloys, including intermetallics, metallic glasses, and high entropy alloys. The journal reports the science and engineering of metallic materials in the following aspects: Theories and experiments which address the relationship between property and structure in all length scales. Physical modeling and numerical simulations which provide a comprehensive understanding of experimental observations. Stimulated methodologies to characterize the structure and chemistry of materials that correlate the properties. Technological applications resulting from the understanding of property-structure relationship in materials. Novel and cutting-edge results warranting rapid communication. The journal also publishes special issues on selected topics and overviews by invitation only.