| Summary: | The exploration of high-entropy alloy development for structural applications is a major requirement for the energy and transportation industries. The systematic strategy of designing high entropy alloys is not complete without considering the desired properties, the selection of the elements, the determination of the composition, and the choice of the manufacturing process for the production of high-performance materials. AlCuFeNiSi high-entropy alloys were prepared via laser metal deposition and arc melting. The nanomechanical and wear characteristics of arc-melted and laser-deposited AlCuFeNiSi high-entropy alloys were comparatively studied because a comprehensive understanding of their mechanical properties is not yet fully understood for structural applications in the energy industry. The empirical relationship between the laser power and the nanohardness was determined using the response surface methodology. The results showed that the high entropy alloys consisted of solid solution BCC and FCC phases. ANOVA showed that laser power had a significant effect on the nanohardness, increasing with an increase in laser power. The optimum laser process parameters to yield the best properties were obtained and backed up with experimental data to achieve a cost-effective design of experiments.
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