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The design of alloys for use in gas turbine engine blades is a complex task that involves balancing multiple objectives and constraints. Candidate alloys must be ductile at room temperature and retain their yield strength at high temperatures, as well as possess low density, high thermal conductivity, narrow solidification range, high solidus temperature, and a small linear thermal expansion coefficient. Traditional Integrated Computational Materials Engineering (ICME) methods are not sufficient for exploring combinatorially-vast alloy design spaces, optimizing for multiple objectives, nor ensuring that multiple constraints are met. In this work, we propose an approach for solving a constrained multi-objective materials design problem over a large composition space, specifically focusing on the Mo-Nb-Ti-V-W system as a representative Multi-Principal Element Alloy (MPEA) for potential use in next-generation gas turbine blades. Our approach is able to learn and adapt to unknown constraints in the design space, making decisions about the best course of action at each stage of the process. As a result, we identify 21 Pareto-optimal alloys that satisfy all constraints. Our proposed framework is significantly more efficient and faster than a brute force approach.

 

Computational methods are increasingly being incorporated into the exploitation of microstructure–property relationships for microstructure-sensitive design of materials. In the present work, we propose non-intrusive materials informatics methods for the high-throughput exploration and analysis of a synthetic microstructure space using a machine learning-reinforced multi-phase-field modeling scheme. We specifically study the interface energy space as one of the most uncertain inputs in phase-field modeling and its impact on the shape and contact angle of a growing phase during heterogeneous solidification of secondary phase between solid and liquid phases. We evaluate and discuss methods for the study of sensitivity and propagation of uncertainty in these input parameters as reflected on the shape of the Cu₆Sn₅intermetallic during growth over the Cu substrate inside the liquid Sn solder due to uncertain interface energies. The sensitivity results rankσ_SI,σ_IL, andσ_IL, respectively, as the most influential parameters on the shape of the intermetallic. Furthermore, we use variational autoencoder, a deep generative neural network method, and label spreading, a semi-supervised machine learning method for establishing correlations between inputs of outputs of the computational model. We clustered the microstructures into three categories (“wetting”, “dewetting”, and “invariant”) using the label spreading method and compared it with the trend observed in the Young-Laplace equation. On the other hand, a structure map in the interface energy space is developed that showsσ_SIandσ_SLalter the shape of the intermetallic synchronously where an increase in the latter and decrease in the former changes the shape from dewetting structures to wetting structures. The study shows that the machine learning-reinforced phase-field method is a convenient approach to analyze microstructure design space in the framework of the ICME.

 

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. 

Uncertainty analysis in the outcomes of model predictions is a key element in decision-based material design to establish confidence in the models and evaluate the fidelity of models. Uncertainty Propagation (UP) is a technique to determine model output uncertainties based on the uncertainty in its input variables. The most common and simplest approach to propagate the uncertainty from a model inputs to its outputs is by feeding a large number of samples to the model, known as Monte Carlo (MC) simulation which requires exhaustive sampling from the input variable distributions. However, MC simulations are impractical when models are computationally expensive. In this work, we investigate the hypothesis that while all samples are useful on average, some samples must be more useful than others. Thus, reordering MC samples and propagating more useful samples can lead to enhanced convergence in statistics of interest earlier and thus, reducing the computational burden of UP process. Here, we introduce a methodology to adaptively reorder MC samples and show how it results in reduction of computational expense of UP processes.