Research paper

Composition Design and Optimization of Microstructure and Properties for an AlCrFeCoNi Low-Expansion Alloy

  • XU Dingfeng ,
  • HAN Feiyang ,
  • JIANG Qicheng ,
  • WANG Huan ,
  • SHANG Liyuan ,
  • LU Yiping
Expand
  • 1 Key Laboratory of Solidification Control and Digital Preparation Technology (Liaoning Province), School of Materials Science and Engineering, Dalian University of Technology, Dalian 116024, China
    2 Engineering Research Center of High-Entropy Alloy Materials (Liaoning Province), School of Materials Science and Engineering, Dalian University of Technology, Dalian 116024, China
LU Yiping, professor, Tel: (0411)84709400, E-mail: luyiping@dlut.edu.cn

Received date: 2025-10-29

  Revised date: 2026-02-13

  Online published: 2026-06-17

Supported by

National Natural Science Foundation of China(U2341261);Joint Program of the Liaoning Provincial Science and Technology Plan(2024JH2/102600019);Innovation Support Program for High-Level Talents of Dalian(2023RG006)

Abstract

Low-expansion alloys are essential structural-functional materials for advanced technologies requiring stringent dimensional stability. They are key components in precision metrology, electronic and microwave devices, cryogenic systems, and ultraprecision manufacturing equipments, where thermal deformation must be strictly controlled. However, conventional Fe-Ni Invar alloys possess insufficient mechanical strength despite their exceptionally low coefficient of thermal expansion, which limits their applicability in load-bearing environments. Design concept of high-entropy alloys offer a promising pathway to overcome this limitation through multiprinciple element alloy design and the associated synergistic effects. In this work, a novel low-expansion alloy, Al1Cr1(Fe65Co4Ni31)98, was developed by introducing Al and Cr into the multicomponent system and applying thermomechanical processing to tailor and refine its microstructure. This design strategy aims to achieve the synergistic optimization of thermal expansion behavior and mechanical performance. Additionally, in situ XRD during heating was employed to elucidate the underlying mechanism and monitor phase evolution. After thermomechanical processing, the alloy exhibited pronounced grain refinement and an increased martensite volume fraction of 8.91%. The microstructure further contained abundant deformation twins and a high density of lattice defects, which collectively enhanced the mechanical strength and thermal stability. Within the temperature range of -60 oC to 100 oC, the coefficient of thermal expansion decreased to 1.10 × 10-6-2.04 × 10-6oC-1. In addition to the Invar effect, this ultralow expansion behavior is attributed to the partial compensation of lattice thermal vibrations by the volume contraction associated with martensite reduction during heating, together with the suppression of anharmonic lattice vibrations induced by interfaces and defects. Meanwhile, the refined microstructure delivered an excellent combination of strength and ductility, achieving a yield strength of 324 MPa, an ultimate tensile strength of 452 MPa, and a fracture elongation greater than 20%. Compared with conventional Invar alloys, the designed alloy exhibited a higher specific strength while maintaining a low coefficient of thermal expansion. These results demonstrate that the synergistic optimization of compositional design and thermomechanical processing enables the exceptional integration of low thermal expansion with robust mechanical properties, offering valuable guidance for developing dimensionally stable structural alloys.

Cite this article

XU Dingfeng , HAN Feiyang , JIANG Qicheng , WANG Huan , SHANG Liyuan , LU Yiping . Composition Design and Optimization of Microstructure and Properties for an AlCrFeCoNi Low-Expansion Alloy[J]. Acta Metall Sin, 2026 , 62(6) : 1021 -1031 . DOI: 10.11900/0412.1961.2025.00348

References

[1] Zhao Z Y. Research on low expansion alloys, preparation technology of core components and key theoretical issues of the spectrometer[D]. Ji'nan: Shandong University, 2017
  赵珍阳. 光谱仪用低膨胀合金和核心部件的制备技术及关键理论问题研究[D]. 济南: 山东大学, 2017
[2] Deng S P, Tang G M, Zhao Y. Study of super-Invar alloy Fe-33Ni-4Co-1.2Nb[J]. J. Funct. Mater., 2010, 41: 677
  邓世平, 唐光明, 赵 彦. Fe-33Ni-4Co-1.2Nb超低膨胀合金研究[J]. 功能材料, 2010, 41: 677
[3] Zhang H, Lin F X, Liu Y, et al. Research progress on Ti-Mn based hydrogen storage alloys[J]. J. Chin. Ceram. Soc., 2024, 52: 1873
  张 贺, 林繁鑫, 刘 勇 等. Ti-Mn系储氢合金的研究进展[J]. 硅酸盐学报, 2024, 52: 1873
[4] Huang G L, He G M, Liu Y, et al. Anisotropy of microstructure, mechanical properties and thermal expansion in Invar 36 alloy fabricated via laser powder bed fusion[J]. Addit. Manuf., 2024, 82: 104025
[5] Lohaus S H, Heine M, Guzman P, et al. A thermodynamic explanation of the Invar effect[J]. Nat. Phys., 2023, 19: 1642
[6] Lin F, Wan J, Yang D Y, et al. Achieving high strength and low thermal expansion coefficient in additively manufactured Invar alloys by leveraging the effect of alloying elements[J]. J. Mater. Sci. Technol., 2026, 254: 81
[7] van Schilfgaarde M, Abrikosov I A, Johansson B. Origin of the Invar effect in iron-nickel alloys[J]. Nature, 1999, 400: 46
[8] Li W J, Lin K, Yan Y, et al. A seawater-corrosion-resistant and isotropic zero thermal expansion (Zr,Ta)(Fe,Co)2 alloy[J]. Adv. Mater., 2022, 34: 2109592
[9] Barron T H K, Collins J G, White G K. Thermal expansion of solids at low temperatures[J]. Adv. Phys., 1980, 29: 609
[10] Wang Q, Dong Y W, Jiang Z H, et al. Enhancing low thermal expansion behavior and strength via induced Zr-rich intermetallic phase in Fe-36Ni Invar Alloy[J]. Mater. Des., 2023, 226: 111644
[11] Sui Q S, He J, Zhang X, et al. Strengthening of the Fe-Ni Invar alloy through chromium[J]. Materials, 2019, 12: 1297
[12] Yeh J W, Chen S K, Lin S J, et al. Nanostructured high-entropy alloys with multiple principal elements: Novel alloy design concepts and outcomes[J]. Adv. Eng. Mater., 2004, 6: 299
[13] Xiong W, Guo A X Y, Zhan S, et al. Refractory high-entropy alloys: A focused review of preparation methods and properties[J]. J. Mater. Sci. Technol., 2023, 142: 196
[14] Yeh J W. Recent progress in high entropy alloys[J]. Ann. Chim. Sci. Mat., 2006, 31: 633
[15] Deng C, Wang T, Wu P W, et al. High entropy materials for catalysis: A critical review of fundamental concepts and applications[J]. Nano Energy, 2024, 120: 109153
[16] Rao Z Y, Tung P Y, Xie R W, et al. Machine learning-enabled high-entropy alloy discovery[J]. Science, 2022, 378: 78
[17] Takeuchi A, Inoue A. Classification of bulk metallic glasses by atomic size difference, heat of mixing and period of constituent elements and its application to characterization of the main alloying element[J]. Mater. Trans., 2005, 46: 2817
[18] Li Z, Jiang H, Wang T, et al. Microstructure evolution of GH2909 low expansion superalloy during heat treatment[J]. Acta Metall. Sin., 2022, 58: 1179
  李 钊, 江 河, 王 涛 等. GH2909低膨胀高温合金热处理中的组织演变行为[J]. 金属学报, 2022, 58: 1179
[19] Yang Z, Liu X P, Fu J, et al. Thermal expansion properties of Fe-Ni-Co super-Invar alloy with Mn[J]. Chin. J. Rare Met., 2013, 37: 501
  杨 正, 刘晓鹏, 符 佳 等. Mn元素对Fe-Ni-Co合金热膨胀性能影响[J]. 稀有金属, 2013, 37: 501
[20] Hart E W. Theory of the tensile test[J]. Acta Metall., 1967, 15: 351
[21] Zaefferer S, Elhami N N. Theory and application of electron channelling contrast imaging under controlled diffraction conditions[J]. Acta Mater., 2014, 75: 20
[22] Mao W Q, Gao S, Gong W, et al. Martensitic transformation-governed Lüders deformation enables large ductility and late-stage strain hardening in ultrafine-grained austenitic stainless steel at low temperatures[J]. Acta Mater., 2024, 278: 120233
[23] Gou J M, Pan Y, Liu X L, et al. Ultrastrong negative thermal expansion compositionally complex alloy[J]. Adv. Mater., 2025, 37: e07767
[24] Zhai Y, Su W L, Guo F J, et al. Experimental and numerical investigation of the yield point phenomenon and strain partitioning behavior in a dual-phase steel with lamellar structure[J]. Mater. Sci. Eng., 2024, A897: 146356
[25] Xi X H, Dong G Q, Wang L Y, et al. Formation mechanism of faulted bands and its effect on α′-martensitic transformation[J]. Mater. Des., 2022, 224: 111321
[26] Zhang Z J, Sheng H W, Wang Z J, et al. Dislocation mechanisms and 3D twin architectures generate exceptional strength-ductility-toughness combination in CrCoNi medium-entropy alloy[J]. Nat. Commun., 2017, 8: 14390
[27] Shi S, Liu C, Wan J F, et al. Thermodynamics of fcc-fct martensitic transformation in Mn-X (X = Cu, Fe) alloys[J]. Mater. Des., 2016, 92: 960
[28] Yang S J, Yang Y, Wang H M. The characteristic and thermodynamics/kinetics of martensitic transformation in Fe50Mn30Co10Cr10 high-entropy alloy during deformation/heat treatment[J]. Adv. Eng. Mater., 2020, 22: 1900868
[29] Liu Q, Ghodrat S, Huisman G, et al. Shape memory alloy actuators for haptic wearables: A review[J]. Mater. Des., 2023, 233: 112264
[30] Song Y Z, Shi N K, Deng S Q, et al. Negative thermal expansion in magnetic materials[J]. Prog. Mater. Sci., 2021, 121: 100835
[31] Nadutov V M, Vashchuk D L, Svystunov Y O, et al. Magnetic and Invar properties of Fe-35%Ni alloy after grinding of structure by hydroextrusion[J]. Funct. Mater., 2012, 19: 334
[32] Drebushchak V A. Thermal expansion of solids: Review on theories[J]. J. Therm. Anal. Calorim., 2020, 142: 1097
[33] Ishida K. Effect of grain size on grain boundary segregation[J]. J. Alloys Compd., 1996, 235: 244
[34] Rogl G, Rogl P F. How severe plastic deformation changes the mechanical properties of thermoelectric skutterudites and half Heusler alloys[J]. Front. Mater., 2020, 7: 600261
[35] Kul M, Akgul B, Karabay Y Z. The relationship of hot and cold rolling processes with the structure and properties of Invar 36[J]. Mater. Chem. Phys., 2023, 295: 127215
[36] Zhang L J, Zhou G Z, Zhao F J. Process of producing expansion alloy Ni29Co18[J]. Chin. J. Nonferrous Met., 1998, 8(suppl.2) : 54
  张丽君, 周广智, 赵福佳. 定膨胀合金Ni29Co18的工艺[J]. 中国有色金属学报, 1998, 8(增刊2): 54
[37] Huang H T, Wang F J, Meng G, et al. Research progress on microstructure and properties of Invar alloy[J]. J. Funct. Mater., 2024, 55: 12084
  黄海堂, 王方军, 孟 刚 等. 因瓦合金组织性能的研究进展[J]. 功能材料, 2024, 55: 12084
[38] Zhang W C. Studies of microstructures and Invar effect of the Fe-Ni-Co alloys[D]. Nanning: Guangxi University, 2013
  张文春. Fe-Ni-Co合金的微结构及其因瓦效应研究[D]. 南宁: 广西大学, 2013
[39] Li P P, Wang A D, Liu C T. A ductile high entropy alloy with attractive magnetic properties[J]. J. Alloys Compd., 2017, 694: 55
[40] Song Y Z, Sun Q, Yokoyama T, et al. Transforming thermal expansion from positive to negative: The case of cubic magnetic compounds of (Zr, Nb)Fe2[J]. J. Phys. Chem. Lett., 2020, 11: 1954
[41] Sun Y M, Cao Y L, Hu S X, et al. Interplanar ferromagnetism enhanced ultrawide zero thermal expansion in Kagome cubic intermetallic (Zr, Nb)Fe2[J]. J. Am. Chem. Soc., 2023, 145: 17096
[42] Cao Y L, Xu Y, Khmelevskyi S, et al. Interplanar magnetic orders and symmetry-tuned zero thermal expansion in Kagomé metal (Zr,Ta)Fe2[J]. Chem. Mater., 2023, 35: 9167
[43] Song Y Z, Sun Q, Xu M, et al. Negative thermal expansion in (Sc,Ti)Fe2 induced by an unconventional magnetovolume effect[J]. Mater. Horiz., 2020, 7: 275
[44] Jing-Ting Z, Yibole H, Narsu B, et al. Structural and magnetic properties of Sc1-xNbxFe2 intermetallics showing anomalous zero thermal expansion[J]. Intermetallics, 2021, 136: 107252
[45] Xu M, Song Y Z, Xu Y J, et al. High-temperature zero thermal expansion in HfFe2+δ from added ferromagnetic paths[J]. Chem. Mater., 2022, 34: 9437
[46] Hao J Z, Shen F R, Hu F X, et al. Realization of ultra-low thermal expansion over a broad temperature interval in Gdx (Dy0.5Ho0.5)1-xCo2 compounds[J]. Scr. Mater., 2020, 185: 181
[47] Li W J, Lin K, Cao Y L, et al. Strong coupling of magnetism and lattice induces near-zero thermal expansion over broad temperature windows in ErFe10V2-xMox compounds[J]. CCS Chem., 2021, 3: 1009
[48] Yu C Y, Lin K, Zhang Q H, et al. An isotropic zero thermal expansion alloy with super-high toughness[J]. Nat. Commun., 2024, 15: 2252
[49] Cui J, Sun Y, Shi K W, et al. Invar effect in the wide and higher temperature range by coherent coupling in Fe-based alloy[J]. Adv. Funct. Mater., 2024, 34: 2309431
Outlines

/