Revisit the VEC rule in high entropy alloys (HEAs) with high-throughput CALPHAD approach and its applications for material design-A case study with Al–Co–Cr–Fe–Ni system

Valence electron concentration (VEC) was treated as a useful parameter to predict solid solution phases, and the VEC rule was proposed for high entropy alloys (HEAs). However, this empirical rule has its limitations, which restricts its applications for phase predictions in HEAs. In this paper, we revisited the empirical VEC rule with the HT-CALPHAD approach in the Al-Co-Cr-Fe-Ni system. Our investigation showed that more than 90% compositions are observed to have BCC structures when 5.7≤VEC≤7.2 and we got 100% FCC structures when VEC≥8.4. Meanwhile, we proposed a data screening procedure to classify and discover the new HEAs. The concepts of average density (ρHEA), highest BCC/FCC temperatures (TBCC/FCCmax), and temperature ranges (∆TBCC/FCC) were introduced as useful data screening criteria to down-screen the candidate alloy compositions for specific engineering applications. In the current work, we have identified three HEA categories (refractory BCC HEAs, light-weight BCC HEA and refractory FCC HEAs) in the Al-Co-Cr-Fe-Ni system and proposed the best candidate in each group. More importantly, our investigation showed the HEA non-equiatomic composition space provides ample opportunities for the discovery of the next-generation HEAs.