Enhancement on Mechanical Properties via Phase Separation Induced by Cu-added High-entropy Alloy Fillers in Metastable Ferrous Medium-entropy Alloy Welds

This study evaluated the weldability of metastable ferrous medium-entropy alloys using high-entropy alloy fillers with various Cu contents and elucidated the strengthening mechanisms at room and cryogenic temperatures by focusing on the formation of a Cu-rich phase (FCC2) in the weld metal (WM). The WM with higher Cu content exhibited more dual face-centered cubic (FCC) phases with dendrite-shaped compositional heterogeneity due to phase separation driven by higher mixing enthalpy. The FCC2 induced greater lattice distortion, resulting in higher nano-hardness and stronger solid-solution hardening. In addition, the increased presence of FCC2 in the WM promoted grain refinement and the formation of additional grain boundaries within individual grains. After cryogenic deformation, the base metal and heat-affected zone in transverse welds underwent martensitic transformation from metastable FCC (transformation-induced plasticity), while the diluted WMs exhibited twinning-induced plasticity because of their higher stacking fault energy (SFE) compared to the base metal. The combination of these deformation mechanisms enhanced the cryogenic tensile properties without compromising ductility. Furthermore, the cryogenic tensile properties of weld with higher Cu content were further improved due to the increased formation of deformation twins in the WM. The consumption of solute Cu to form more Cu-rich FCC2 resulted in compositional variations in the matrix (FCC1), leading to a further reduction in the SFE of FCC1 and the activation of additional twin formation. Additionally, FCC2 with a relatively higher SFE refined secondary twins as well as contributed to further dislocation accumulation. This study suggests that the formation of Cu-rich phase in the WM can enhance mechanical properties at both room and cryogenic temperatures and provides a valuable approach for the future development of welding materials to improve the mechanical properties of FCC-based welded structures.