Surface Integrity Analysis in Grinding of Dual-Phase High-Entropy Alloy

High-entropy alloys (HEAs) are highly anticipated because of their superb properties in strength, hardness, wear resistance, etc. However, compared with numerous studies on the design and properties of HEAs, the machinability research of HEAs is extremely rare, which limits the application of HEAs. In this work, grinding experiments of (FeCoNi)₈₆Al₇Ti₇ dual-phase HEA workpieces were carried out, and the results are analyzed from a general machinability perspective (the machining parameters’ effect on grinding force and surface roughness) to a more in-depth perspective, including grinding-induced changes in morphology and microstructure on the ground surface and subsurface. With scanning electron microscope (SEM) and electron backscatter diffraction (EBSD) information of subsurface, the deformation mechanisms have been studied, including the role of the second-phase (Ni₂AlTi) in the grinding process, the material removal modes of the different phases, and the morphology of the nanoprecipitates in the matrix, based on the completely opposite properties of different phases in HEA. It is noticed that the hard and brittle property of the second phase brings support to the material, reduces the plastic deformation, and also makes its own removal brittle, while the plastic matrix experiences shear deformation in grinding, which makes the nanoprecipitates in it assume different morphologies. These detailed findings could be of help to understand the effect of grinding on material properties so as to improve the machining quality of this material.