Abstract—High-Entropy Alloys (HEAs) have gained attention for their exceptional mechanical properties, corrosion resistance, and unique microstructure. However, welding HEAs remains challenging, attributed to intricate microstructures, inadequate thermal conductivity, and elevated melting points. This review systematically summarizes recent advances in metal welding of HEAs with both similar and dissimilar alloys, including stainless steel, titanium alloys, aluminum alloys, and nickel-based alloys. Welding techniques, including Gas Metal Arc Welding (GMAW), Laser Welding (LW), Electron Beam Welding (EBW), and Gas Tungsten Arc Welding (GTAW) are critically compared in terms of joint microstructure, mechanical performance, and corrosion behavior. The influence of filler composition, heat treatment, and process parameters on weld quality are discussed. Key challenges, including microstructure evolution under complex service conditions and controlling brittle intermetallic phases, are identified. Finally, potential research directions and application prospects of HEA welding in advanced manufacturing are outlined.

Keywords—high-entropy alloys, welding processes, microstructure, mechanical properties

Cite: Min Li, Monsak Pimsarn, Varesa Chuwattanakul, and Smith Eiamsa-ard, "Recent Advances in Welding Processes for High-Entropy Alloys: A Comprehensive Review," International Journal of Mechanical Engineering and Robotics Research, Vol. 15, No. 2, pp. 232-247, 2026. doi: 10.18178/ijmerr.15.2.232-247

Copyright © 2026 by the authors. This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).