Applicability of Extreme Vertices Design in the Compositional Optimization of 3D-Printed Lightweight High-Entropy-Alloy/B4C/ZrO2/Titanium Trihybrid Aero-Composite

Recent studies have shown the benefits of utilizing ceramic particles as reinforcement in metal alloys; nevertheless, certain drawbacks, including loss of ductility, embrittlement, and decreases in toughness, have been noted. For the objective of obtaining balanced performance, experts have suggested the addition of metal particles as supplement to the ceramic reinforcement. Consequently, high-performance metal hybrid composites have been developed. However, achieving the optimal mix for the reinforcement combination with regards to the optimal performance of developed composite remains a challenge. This research aimed to determine the optimal mixture of Al50Cu10Sn5Mg20Zn10Ti5 lightweight high-entropy alloy (LHEA), B4C, and ZrO2 for the fabrication of trihybrid titanium composites via direct laser deposition. A mixture design was involved in the experimental design, and experimental data were modeled and optimized to achieve the optimal performance of the trihybrid composite. The ANOVA, response surface plots, and ternary maps analyses of the experimental results revealed that various combinations of reinforcement particles displayed a variety of response trends. Moreover, the analysis showed that these reinforcements significantly contributed to the magnitudes and trends of the responses. The generated models were competent for predicting response, and the best formulation consisted of 8.4% LHEA, 1.2% B4C, and 2.4% ZrO2.