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Additive manufacturing (AM), particularly Laser Powder Bed Fusion (L-PBF), holds the potential for producing high-quality parts with intricate details. However, optimizing process parameters for arbitrary alloy chemistries to ensure printability remains challenging. This study evaluates machine learning (ML) models to predict a material’s amenability to L-PBF via the printability index, focusing on High Entropy Alloy (HEA) spaces. The printability index of a material is defined as the percentage of the defect-free L-PBF processing window. Our study revealed that CatBoost Regressors and Random Forest Regressors excel in predictive accuracy, consistently yielding predictions with competitive error metrics such as the mean absolute error (MAE), mean squared error (MSE), root mean squared error (RMSE), and . In addition, competitive rank-order coefficients such as Spearman and Kendall-tau demonstrated that these models are not overfitting. Feature importance analysis using Shapley Additive Explanations (SHAP) highlighted key material properties influencing printability, such as kinetic viscosity, average Pauling electronegativity, and electric conductivity. While both models performed comparably in predictive accuracy, the Random Forest Regressor demonstrated superior computational efficiency, particularly with large datasets. Robustness tests confirmed its reliability across different test sizes. This research underscores the importance of considering factors like computational efficiency, interpretability, and robustness to noise when selecting ML models for L-PBF material printability prediction. Leveraging Integrated Computational Materials Engineering (ICME) methodologies and ML models can significantly optimize process parameters and material properties, paving the way for innovative solutions in L-PBF. This approach accelerates the assessment of new materials and optimizes existing ones for L-PBF processes, contributing significantly to the field of AM. 

Multi-Principal Element Alloys (MPEAs) have emerged as an exciting area of research in materials science in the 2020s, owing to the vast potential for discovering alloys with unique and tailored properties enabled by the combinations of elements. 

Multi-principal-element alloys (MPEAs) based on 3d-transition metals show remarkable mechanical properties. The stacking fault energy (SFE) in face-centered cubic (fcc) alloys is a critical property that controls underlying deformation mechanisms and mechanical response. Here, we present an exhaustive density-functional theory study on refractory- and copper-reinforced Cantor-based systems to ascertain the effects of refractory metal chemistry on SFE. We find that even a small percent change in refractory metal composition significantly changes SFEs, which correlates favorably with features like electronegativity variance, size effect, and heat of fusion. For fcc MPEAs, we also detail the changes in mechanical properties, such as bulk, Young’s, and shear moduli, as well as yield strength. A Labusch-type solute-solution-strengthening model was used to evaluate the temperature-dependent yield strength, which, combined with SFE, provides a design guide for high-performance alloys. We also analyzed the electronic structures of two down-selected alloys to reveal the underlying origin of optimal SFE and strength range in refractory-reinforced fcc MPEAs. These new insights on tuning SFEs and modifying composition-structure-property correlation in refractory- and copper-reinforced MPEAs by chemical disorder, provide a chemical route to tune twinning- and transformation-induced plasticity behavior. 

Additive Manufacturing (AM) has opened new frontiers for the design of refractory high-entropy alloys (HEAs) for high-temperature applications. The thermal conductivity of the AM feedstock is among the most important thermo-physical properties that control the melting and solidification process. Despite its significance, there remains a notable gap in both computational and experimental research concerning the thermal conductivity of HEAs. Here, we use density functional theory (DFT) to systematically investigate the alloying effects on the transport properties of Ti-Cr-Mo-W-V-Nb-Ta RHEAs, including electrical and thermal conductivities and the Seebeck coefficient. The relaxation time of charge carriers is a key underlying parameter determining thermal conductivity that is exceedingly challenging to predict from first principles alone, and we thus follow the approach by Mukherjee, Satsangi, and Singh [Chem Mater 32, 6507 (2022)] to optimize the relaxation time for RHEAs. We validated thermal conductivity predictions on elemental solids, binary and ternary alloys, and RHEAs and compared them against thermodynamic (CALPHAD) predictions and our experiments with good correlations. To understand observed trends in thermal conductivity, we assessed the phase stability, electronic structure, phonon, and intrinsic- and tensile strength of down-selected RHEAs. Our electronic structure and phonon results connect well with the observed compositional trends for thermal transport in RHEAs. Our DFT assessment and CALPHAD predictions provide a unique design guide for RHEAs with tailored thermal conductivity, a critical consideration for AM and thermal-management applications. 

Refractory high entropy alloys (RHEAs) have gained significant attention in recent years as potential replacements for Ni-based superalloys in gas turbine applications. Improving their properties, such as their high-temperature yield strength, is crucial to their success. Unfortunately, exploring this vast chemical space using exclusively experimental approaches is impractical due to the considerable cost of the synthesis, processing, and testing of candidate alloys, particularly at operation-relevant temperatures. On the other hand, the lack of reasonably accurate predictive property models, especially for high-temperature properties, makes traditional Integrated Computational Materials Engineering (ICME) methods inadequate. In this paper, we address this challenge by combining machine-learning models, easy-to-implement physics-based models, and inexpensive proxy experimental data to develop robust and fast-acting models using the concept of Bayesian updating. The framework combines data from one of the most comprehensive databases on RHEAs (Borg et al., 2020) with one of the most widely used physics-based strength models for BCC-based RHEAs (Maresca and Curtin, 2020) into a compact predictive model that is significantly more accurate than the state-of-the-art. This model is cross-validated, tested for physics-informed extrapolation, and rigorously benchmarked against standard Gaussian process regressors (GPRs) in a toy Bayesian optimization problem. Such a model can be used as a tool within ICME frameworks to screen for RHEAs with superior high-temperature properties. The code associated with this work is available at: https://codeocean.com/capsule/7849853/tree/v2.