Precise microstructural tailoring in high-entropy alloys for superior mechanical performances

Optimizing high-entropy alloys (HEAs) for multifunctional applications demands extensive composition and post-processing experimentation. In this study, an atomic manufacturing (AM) strategy that tunes energy distribution and configurations of atomic clusters to design NbMoTaWNi HEAs with gradient heterogeneous structure is presented. The optimized alloy demonstrates unprecedented yield strength (11.42 GPa) and homogeneous deformation (20% strain), surpassing conventional strength-plasticity trade-offs. Mechanistic analysis reveals that Ta-rich amorphous thin-walled structures with density gradients enable homogeneous plastic flow through synergistic stress localization in these structures combined with interfacial strain buffering. This AM engineering paradigm opens avenues for customizing extreme-environment materials through atomic-scale structure control. Impact statement Atomic-manufactured NbMoTaWNi HEA with gradient heterostructures achieves ultrahigh strength and homogeneous deformation via Ta-rich thin-wall-enabled stress localization and shear-induced structural regeneration, overcoming trade-offs and advancing material design.