Thermodynamics-guided high-throughput discovery of magnetic high-entropy alloys fabricated by spark plasma sintering at different temperatures

This study presents a high-throughput, thermodynamics-guided framework for the discovery of novel magnetic high-entropy alloys (HEA). High-throughput CALPHAD simulations were employed to predict the equilibrium phases and Curie temperatures across a broad compositional space, including benchmark systems. The computational results were integrated with statistical data analysis to identify candidate compositions with optimal magnetic properties. The selected Fe₄₂Co₁₇Ni₁₂Al₁₇Cu₆Ti₆ HEA was fabricated by spark plasma sintering at various temperatures. For direct comparison, a reference Alnico 5 alloy was synthesized under the same processing conditions at 1273 K. The as-sintered HEA exhibited superior magnetic properties, with a maximum energy product (BH_max) of 4.4 kJ/m³ and coercivities (H_cj = 35.7 kA/m, H_cb = 33.4 kA/m) exceeding those of the Alnico 5 benchmark (BH_max = 3.3 kJ/m³, H_cj = 30.3 kA/m, H_cb = 27.9 kA/m). Furthermore, the HEA exhibited superior thermal stability, maintaining its remanence with a more gradual decline up to 1030 K, in contrast to Alnico 5, which underwent a rapid decrease above 870 K. This work establishes a versatile approach for accelerating the design of sustainable magnetic materials with tailored properties, effectively bridging high-throughput thermodynamic modeling and advanced manufacturing.