To enhance efficiencies and reduce CO2 emissions in applications such as jet-engines and gas turbines, alloys that withstand high temperatures are essential. High entropy alloys (HEA) containing refractory elements such as Nb, Ta, and Mo can offer superior high temperature mechanical properties. This work has focused on one of these alloys, i.e. AlMo0.5NbTa0.5ZrTi which have a comparable microstructure to Ni-based super alloys containing a nanoscale BCC/B2 structure with exceptional mechanical properties even at elevated temperatures and in some cases exceeding Ni-super alloys. However this alloy cannot be manufactured by conventional techniques since these have elements with very high (Nb, Ta, Mo), high (Zr, Ti) and low (Al) melting temperatures. Therefore, a novel technique, field assisted sintering technique (FAST) – Forge, is used to make parts from powders of this alloy. FAST-Forge operates efficiently by utilising lower processing temperatures and shorter processing times, which produces parts with high density and good mechanical properties. Therefore, this process presents a more sustainable manufacturing route for the above-mentioned alloy.

The microstructure of the parts produced is examined using characterisation techniques such as XRD and SEM to understand and link the process conditions to the microstructure and their corresponding mechanical properties. A comparison of the microstructure development and the mechanical properties obtained by FAST-forge and conventional manufacturing techniques is discussed in detail.