Abstract
In this study, an effective and sustainable casting process for high entropy alloys (HEAs) was fabricated from recovered electronic waste. To determine the properties of the resultant alloy, microstructural characterization, alloy composition and the feasibility evaluation was carried out. According to the study, HEAs with multi-phase structures, such as FCC, BCC, and intermetallic phases, may be effectively produced from e-waste. While elements like Al, Mn, Cr, and Si improved mechanical and thermal properties, compositional analysis verified that copper was the main matrix phase. The alloy composition influenced micro-hardness through solid solution strengthening (Cu-Sn-Mn matrix), intermetallic phase formation (NiCuMnAl, CrSi), and carbide precipitation (CrC), while the manufacturing process (crucible induction melting and cooling rates) affected phase distribution, grain refinement, and porosity, leading to hardness variations from 371 HV to 554 HV. Crucible induction melting was used in the casting process; however it had challenges with controllable temperature, which resulted in segregation and irregular phase development. However, the study demonstrated that recovered e-waste may be used to produce HEA sustainably while also providing information on improved alloy design and material recovery. Through this effort, the field of high-entropy materials is advanced and ecologically friendly production procedures are developed.