An active machine learning approach for optimal design of magnesium alloys using Bayesian optimisation

In the pursuit of magnesium (Mg) alloys with targeted mechanical properties, a multi-objective Bayesian optimisation workflow is presented to enable optimal Mg-alloy design. A probabilistic Gaussian process regressor model was trained through an active learning loop, while balancing the exploration and exploitation trade-off via an acquisition function of the upper confidence bound. New candidate alloys suggested by the optimiser within each iteration were appended to the training data, and the performance of this sequential strategy was validated via a regret analysis. Using the proposed approach, the dependency of the prediction error on the training data was overcome by considering both the predictions and their associated uncertainties. The method developed here, has been packaged into a web tool with a graphical user-interactive interface (GUI) that allows the proposed optimal Mg-alloy design strategy to be deployed.

Fatigue behavior of additively manufactured Ti3Al2V alloy

This study measured the tensile, compression, and fatigue behavior of additively manufactured Ti3Al2V as a function of build orientation. Ti3Al2V alloy was prepared by mixing commercially pure titanium (CpTi) and Ti6Al4V in 1:1 wt. ratio. Laser powder bed fusion (L-PBF) based additive manufacturing (AM) technique was used to fabricate the samples. Tensile tests resulted in an ultimate strength of 989 ± 8 MPa for Ti3Al2V. Ti6Al4V 90° orientation samples showed a compressive yield strength of 1178 ± 33 MPa, and that for Ti3Al2V 90° orientation was 968 ± 24 MPa. Varying the build orientation to account for anisotropy, Ti32-45° and Ti32-0° displayed similar compressive yield strength values of 1071 ± 16 and 1051± 18 MPa, respectively, higher than Ti32-90°. Fatigue loading revealed an endurance limit (10 million cycles) of 250 MPa for Ti6Al4V and 219 MPa for Ti3Al2V built at 90° orientations. The effect of the build orientation was significant under fatigue loading; Ti3Al2V built at 45° displayed an endurance limit of 387.5 MPa, and 0° showed 512 MPa; more than two-fold increment in endurance limit was observed. Our results show the potential of Ti3Al2V alloy for orthopedic devices, replacing Ti6Al4V alloy, particularly in load-bearing applications.

Accelerated discovery of high-performance Al-Si-Mg-Sc casting alloys by integrating active learning with high-throughput CALPHAD calculations

Scandium is the best alloying element to improve the mechanical properties of industrial Al-Si-Mg casting alloys. Most literature reports devote to exploring/designing optimal Sc additions in different commercial Al-Si-Mg casting alloys with well-defined compositions. However, no attempt to optimize the contents of Si, Mg, and Sc has been made due to the great challenge of simultaneous screening in high-dimensional composition space with limited experimental data. In this paper, a novel alloy design strategy was proposed and successfully applied to accelerate the discovery of hypoeutectic Al-Si-Mg-Sc casting alloys over high-dimensional composition space. Firstly, high-throughput CALculation of PHAse Diagrams (CALPHAD) solidification simulations of ocean of hypoeutectic Al-Si-Mg-Sc casting alloys over a wide composition range were performed to establish the quantitative relation 'composition-process-microstructure'. Secondly, the relation 'microstructure-mechanical properties' of Al-Si-Mg-Sc hypoeutectic casting alloys was acquired using the active learning technique supported by key experiments designed by CALPHAD and Bayesian optimization samplings. After a benchmark in A356-xSc alloys, such a strategy was utilized to design the high-performance hypoeutectic Al-xSi-yMg alloys with optimal Sc additions that were later experimentally validated. Finally, the present strategy was successfully extended to screen the optimal contents of Si, Mg, and Sc over high-dimensional hypoeutectic Al-xSi-yMg-zSc composition space. It is anticipated that the proposed strategy integrating active learning with high-throughput CALPHAD simulations and key experiments should be generally applicable to the efficient design of high-performance multi-component materials over high-dimensional composition space.

Design biodegradable Zn alloys: Second phases and their significant influences on alloy properties

Alloying combined with plastic deformation processing is widely used to improve mechanical properties of pure Zn. As-cast Zn and its alloys are brittle. Beside plastic deformation processing, no effective method has yet been found to eliminate the brittleness and even endow room temperature super-ductility. Second phase, induced by alloying, not only largely determines the ability of plastic deformation, but also influences strength, corrosion rate and cytotoxicity. Controlling second phase is important for designing biodegradable Zn alloys. In this review, knowledge related to second phases in biodegradable Zn alloys has been analyzed and summarized, including characteristics of binary phase diagrams, volume fraction of second phase in function of atomic percentage of an alloying element, and so on. Controversies about second phases in Zn-Li, Zn-Cu and Zn-Fe systems have been settled down, which benefits future studies. The effects of alloying elements and second phases on microstructure, strength, ductility, corrosion rate and cytotoxicity have been neatly summarized. Mg, Mn, Li, Cu and Ag are recommended as the major alloying elements, owing to their prominent beneficial effects on at least one of the above properties. In future, synergistic effects of these elements should be more thoroughly investigated. For other nutritional elements, such as Fe and Ca, refining second phase is a matter of vital concern.

Comparative in vitro study on binary Mg-RE (Sc, Y, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu) alloy systems

Correct selection of alloying elements is important for developing novel biodegradable magnesium alloys with superior mechanical and biological performances. In contrast to various reports on nutrient elements (Ca, Zn, Sr, etc.) as alloying elements of biomedical magnesium alloys, there is limited information about how to choose the right rare earth elements (REEs) as alloying elements of magnesium. In this work, 16 kinds of REEs were individually added into Mg, including Sc, Y, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Du, Ho, Er, Tm, Yb and Lu, to fabricate binary Mg-RE model alloys with different composition points. Under the same working history, comparative studies were undertaken and the impact of each kind of rare earth element on the microstructure, mechanical property, corrosion behavior and biocompatibility of Mg were investigated. The corresponding influence level for the 16 kinds of REEs were ranked. The results showed that the second phases were detected in some Mg-RE alloys, which were mainly composed of Mg₁₂RE. By adding different REEs into Mg with proper contents, the mechanical properties of resulting Mg-RE binary alloys could be adjusted in wide range. The corrosion resistance of Mg-light REE alloys was generally better than Mg-heavy REE alloys. As for biocompatibility, Mg-RE model alloys showed no cytotoxic effect on MC3T3-E1 cells. The hemolysis rates of all experimental Mg-RE model alloys were lower than 5% except for Mg-Lu alloy model. In general, the addition of different REEs into Mg could improve its performance from different aspects. This work provides a better understanding on suitable REEs as alloying elements for magnesium, and the future R&D direction on biomedical Mg-RE alloys was proposed. STATEMENT OF SIGNIFICANCE: In contrast to various reports on nutrient elements (Ca, Zn, Sr, etc.) as alloying elements of biomedical magnesium alloys, until now there is limited information about how to choose the right rare earth elements (REEs) as alloying elements of magnesium. In this work, comparative studies were undertaken by individually adding 16 kinds of REEs, including Sc, Y, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Du, Ho, Er, Tm, Yb and Lu, into Mg to fabricate binary Mg-RE model alloys, with different composition points, then the impact of each kind of rare earth element on the microstructure, mechanical property, corrosion behavior and biocompatibility of Mg under the same working history were investigated, and the corresponding influence level for the 16 kinds of REEs were ranked. This work provides a better understanding on suitable REEs as alloying elements for magnesium, and the future R&D direction on biomedical Mg-RE alloys was proposed.

Data of the maximum solid solubility limits of binary systems of elements

This paper gives the available data for the maximum equilibrium solubility limits of each of the first 83 elements (H to Bi) of the periodic table in each of the others. This is expressed in the form of the maximum value of the equilibrium solid solubility for terminal solid solutions, expressed in atomic percentage (at%), occurring at any temperature where the room temperature phase of the pure element acting as the solvent is stable. The values thus represent the compatibility between different elements in the formation of alloys and similar combinations, and will be of use for research into fundamental solid state physics relating to elemental interactions, for the interpretation of phase structures in materials research and for the design of alloys and materials involving elemental mixing of the elements.

Design and fabrication of Ti-Zr-Hf-Cr-Mo and Ti-Zr-Hf-Co-Cr-Mo high-entropy alloys as metallic biomaterials

Novel TiZrHfCr_0.2Mo and TiZrHfCo_0.07Cr_0.07Mo high-entropy alloys for metallic biomaterials (bio-HEAs) were developed based on the combination of Ti-Nb-Ta-Zr-Mo alloy system and Co-Cr-Mo alloy system as commercially-used metallic biomaterials. Ti-Zr-Hf-Cr-Mo and Ti-Zr-Hf-Co-Cr-Mo bio-HEAs were designed using (a) a tree-like diagram for alloy development, (b) empirical alloy parameters for solid-solution-phase formation, and (c) thermodynamic calculations focused on solidification. The newly-developed bio-HEAs overcomes the limitation of classical metallic biomaterials by the improvement of (i) mechanical hardness and (ii) biocompatibility all together. The TiZrHfCr_0.2Mo and TiZrHfCo_0.07Cr_0.07Mo bio-HEAs showed superior biocompatibility comparable to that of commercial-purity Ti. The superior biocompatibility, high mechanical hardness and low liquidus temperature for the material processing in TiZrHfCr_0.2Mo and TiZrHfCo_0.07Cr_0.07Mo bio-HEAs compared with the Ti-Nb-Ta-Zr-Mo bio-HEAs gave the authenticity of the application of bio-HEAs for orthopedic implants with multiple functions.

Developing high strength and ductility in biomedical Co-Cr cast alloys by simultaneous doping with nitrogen and carbon

There is a strong demand for biomedical Co-Cr-based cast alloys with enhanced mechanical properties for use in dental applications. We present a design strategy for development of Co-Cr-based cast alloys with very high strength, comparable to that of wrought Co-Cr alloys, without loss of ductility. The strategy consists of simultaneous doping of nitrogen and carbon, accompanied by increasing of the Cr content to increase the nitrogen solubility. The strategy was verified by preparing Co-33Cr-9W-0.35N-(0.01-0.31)C (mass%) alloys. We determined the carbon concentration dependence of the microstructures and their mechanical properties. Metal ion release of the alloys in an aqueous solution of 0.6% sodium chloride (NaCl) and 1% lactic acid was also evaluated to ensure their corrosion resistance. As a result of the nitrogen doping, the formation of a brittle σ-phase, a chromium-rich intermetallic compound, was significantly suppressed. Adding carbon to the alloys resulted in finer-grained microstructures and carbide precipitation; accordingly, the strength increased with increasing carbon concentration. The tensile ductility, on the other hand, increased with increasing carbon concentration only up to a point, reaching a maximum at a carbon concentration of ∼0.1mass% and decreasing with further carbon doping. However, the alloy with 0.31mass% of carbon exhibited 14% elongation and also possessed very high strength (725MPa in 0.2% proof stress). The addition of carbon did not significantly degrade the corrosion resistance. The results show that our strategy realizes a novel high-strength Co-Cr-based cast alloy that can be produced for advanced dental applications using a conventional casting procedure.

STATEMENT OF SIGNIFICANCE

The present study suggested a novel alloy design concept for realizing high-strength Co-Cr-based cast alloys. The proposed strategy is beneficial from the practical point of view because it uses conventional casting approach-a simpler, more cost-effective, industrially friendly manufacturing process than other manufacturing processes such as thermomechanical processing or powder metallurgy. The developed alloys showed the excellent strength-ductility balance and significantly high strength comparable to that of wrought Co-Cr-Mo alloys, while maintaining acceptable ductility and good corrosion resistance. We described the relationship between microstructures and mechanical and corrosion prosperities of the developed alloys; this provides the fundamental aspect of the proposed strategy and will be helpful for further investigations or industrial realization of the proposed strategy.