Fabrication of high-entropy alloy wire and multi-principal element alloy wire

1. A method of fabricating a metallic wire, the method comprising:

combining, to form at least a portion of a preform, (i) one or more first metal powders each comprising a plurality of substantially spherical particles, and (ii) one or more second metal powders each comprising a plurality of non-spherical particles, the one or more second metal powders being mixed with the one or more first metal powders such that a composition of the preform is substantially homogeneous along a length of the preform; and

reducing a diameter of the preform via one or more mechanical deformation processes, thereby forming a metallic wire,

wherein (i) the metallic wire comprises a high-entropy alloy comprising five or more metallic elements or a multi-principal element alloy comprising four or more metallic elements, (ii) each first metal powder comprises at least one of the metallic elements, (iii) each second metal powder comprises at least one of the metallic elements, (iv) the substantially spherical particles are spherical to within ±10% in any direction such that an eccentricity in any direction does not exceed 10%, and (v) the non-spherical particles (a) are elongated with an aspect ratio of at least 2:1, (b) are acicular, (c) have at least one flat surface, (d) are flakes, (e) have at least one corner or vertex, or (f) are polyhedral.

2. The method of claim 1 , wherein the metallic elements comprise at least four of Nb, Ta, Mo, W, Ti, Hf, V, Zr, Al, or Cr.

3. The method of claim 1 , wherein the non-spherical particles of at least one second metal powder are angular flakes.

4. The method of claim 1 , wherein the one or more mechanical deformation processes comprise at least one of drawing, pilgering, swaging, extrusion, or rolling.

5. The method of claim 1 , wherein the preform comprises one or more metallic tubes surrounding the one or more first metal powders and the one or more second metal powders, each metallic tube comprising at least one of the metallic elements.

6. The method of claim 1 , wherein the one or more first metal powders and the one or more second metal powders are combined within one or more sacrificial tubes, and further comprising removing the one or more sacrificial tubes after reducing the diameter of the preform.

7. The method of claim 1 , wherein at least one said first metal powder is provided by a process comprising:

providing a plurality of metal particulates;

feeding the metal particulates into a plasma, thereby at least partially melting the metal particulates; and

cooling the at least partially melted metal particulates to form substantially spherical particles.

8. The method of claim 1 , wherein at least one said second metal powder is provided by a process comprising:

hydrogenating metal to form a metal hydride;

mechanically grinding the metal hydride into a plurality of non-spherical particles; and

dehydrogenating the non-spherical metal hydride particles.

9. The method of claim 1 , wherein at least one first metal powder is an elemental powder consisting essentially of one of the metallic elements.

10. The method of claim 1 , wherein at least one first metal powder is an alloy powder consisting essentially of two or more of the metallic elements.

11. The method of claim 1 , wherein at least one second metal powder is an elemental powder consisting essentially of one of the metallic elements.

12. The method of claim 1 , wherein at least one second metal powder is an alloy powder consisting essentially of two or more of the metallic elements.

13. The method of claim 1 , wherein an oxygen concentration of the one or more first metal powders is 300 ppm or less.

14. The method of claim 1 , wherein an oxygen concentration of the one or more second metal powders is 300 ppm or less.

15. The method of claim 1 , wherein an average particle size of at least one of the first metal powders ranges from approximately 15 μm to approximately 45 μm.

16. The method of claim 1 , wherein an average particle size of at least one of the second metal powders is greater than approximately 50 μm.

17. The method of claim 6 , wherein removing the one or more sacrificial tubes comprises at least one of melting or etching.

18. The method of claim 1 , further comprising:

translating a tip of the wire relative to a platform;

thereduring, melting a tip of the wire with an energy source to form a molten bead comprising the metallic elements, whereby the bead cools to form at least a portion of a layer of a three-dimensional part; and

repeating the above steps one or more times to produce the three-dimensional part,

wherein the three-dimensional part comprises the high-entropy alloy or the multi-principal element alloy.