Fabrication of High Entropy Alloys by Modern Metallurgical Methods

Abstract

Modern metallurgical methods used in the production of high entropy alloys (HEA) are of critical importance for the successful use of this innovative material class in industrial applications. This study comprehensively examines a wide spectrum of production technologies, from conventional melting and casting techniques to advanced manufacturing methods. In addition to conventional methods such as arc melting, induction melting, and vacuum melting systems, advanced manufacturing methods such as mechanical alloying, spark plasma sintering (SPS), magnetron sputtering, and additive manufacturing technologies are discussed in detail. The process parameters, advantages, limitations, and specific applications of each manufacturing technique in HEA production are systematically analyzed. The study focuses on controlling undesirable processes such as segregation, evaporation, and oxidation, which occur due to the complex nature of multi-component systems. While conventional methods have a wide range of applications from laboratory scale to industrial scale, it has been demonstrated that solid state processes and additive manufacturing technologies offer unique advantages, especially in terms of net-shape production, nano-structural control, and achieving complex geometries. This comprehensive review provides critical guidance for the optimization of modern metallurgical methods used in HEAs production and for the selection of the correct technique for industrial applications. © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2026.