We report the fabrication of a L12-strengthened high-entropy alloy (HEA), Ni27.7Cr24Co23.5Fe15.7Mo1.6Al3Ti4.5 (at. %), using binder jet 3D printing (BJ3DP), consisting of printing and subsequent sintering. The resulting alloy exhibits high strength and corrosion resistance. This study systematically investigates the interdependence among processing parameters, microstructural evolution, and resulting properties. Optimal printing parameters (50 μm layer thickness, 50 % binder saturation, 3 mm/s spreading speed) yielded a green density of ∼58 %. Subsequent sintering at 1280 °C for 4 h achieved the highest relative density of ∼99.2 %. The microstructural evolution during sintering governed L12 precipitation and porosity, which in turn dictated the mechanical properties and corrosion resistance. Superior performance was achieved after sintering at 1280 °C. This condition produced enhanced densification and refined L12 precipitates, resulting in a yield strength of ∼726 MPa, ultimate tensile strength of ∼1112 MPa, and elongation of ∼16.5 %. Conversely, sintering at 1290 °C caused partial melting and precipitate coarsening, which degraded both strength and corrosion resistance. Electrochemical tests in 3.5 wt% NaCl solution confirmed the optimal corrosion resistance of the 1280 °C sample, which exhibited a pitting potential (∼0.97 VSCE) significantly higher than that of 316L stainless steel. In contrast, samples sintered below 1280 °C showed excessive porosity, while those above 1290 °C exhibited microstructural instability, both leading to severe pitting and galvanic corrosion. These results establish clear process–microstructure–property relationships for BJ3DP-fabricated HEAs and demonstrate a viable pathway for tailoring multifunctional performance through controlled processing.
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