Design of a Ferritic Heat-Resistant Alloy with Improved Corrosion Resistance and Ductility
High-entropy alloys (HEA) have emerged as promising structural materials for use in extreme environments where conventional alloys face limitations. In this study, ferritic Fe-Al-Cr-Ni-Ti alloys were developed by employing the HEA design concept to promote coherent L21 precipitation within a BCC matrix. The systematic variation of Al content enhanced lattice coherency, precipitation strengthening, and the rapid formation of protective Al2O3 scales. The alloy with 16 at% Al exhibited superior high-temperature mechanical performance, showing a yield strength of approximately 400 MPa and ~5 % uniform elongation at 700 °C, exceeding the use temperature limit of conventional steels. Steam oxidation tests demonstrated the formation of dense, continuous alumina films, while hot rolling and grain refinement effectively improved room-temperature ductility. These findings indicate that Fe-Al-Cr-Ni-Ti alloys offer a cost-effective pathway to achieve a balanced combination of heat resistance, corrosion resistance, and mechanical processability, suggesting their potential as strong candidates for next-generation energy and high-temperature structural applications.