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At least 37 records · Page 2

Multi-fidelity microstructure-induced uncertainty quantification by advanced Monte Carlo methods

Quantifying uncertainty associated with the microstructure variation of a material can be a computationally daunting task, especially when dealing with advanced constitutive models and fine mesh resolutions in the crystal plasticity finite element method (CPFEM). Numerous studies have been conducted regarding the sensitivity of material properties and performance to the mesh resolution and choice of constitutive model. However, a unified approach that accounts for various fidelity parameters, such as mesh resolutions, integration time-steps and constitutive models simultaneously is currently lacking. Further, this paper proposes a novel uncertainty quantification (UQ) approach for computing the properties and performance of homogenized materials using CPFEM, that exploits a hierarchy of approximations with different levels of fidelity. In particular, we illustrate how multi-level sampling methods, such as multi-level Monte Carlo (MLMC) and multi-index Monte Carlo (MIMC), can be applied to assess the impact of variations in the microstructure of polycrystalline materials on the predictions of homogenized materials properties. We show that by adaptively exploiting the fidelity hierarchy, we can significantly reduce the number of microstructures required to reach a certain prescribed accuracy. Finally, we show how our approach can be extended to a multi-fidelity framework, where we allow the underlying constitutive model to be chosen from either a phenomenological plasticity model or a dislocation-density-based model.

36 MATERIALS SCIENCE↗

Microstructure-Sensitive Uncertainty Quantification for Crystal Plasticity Finite Element Constitutive Models Using Stochastic Collocation Methods

Uncertainty quantification (UQ) plays a major role in verification and validation for computational engineering models and simulations, and establishes trust in the predictive capability of computational models. In the materials science and engineering context, where the process-structure-property-performance linkage is well known to be the only road mapping from manufacturing to engineering performance, numerous integrated computational materials engineering (ICME) models have been developed across a wide spectrum of length-scales and time-scales to relieve the burden of resource-intensive experiments. Within the structure-property linkage, crystal plasticity finite element method (CPFEM) models have been widely used since they are one of a few ICME toolboxes that allows numerical predictions, providing the bridge from microstructure to materials properties and performances. Several constitutive models have been proposed in the last few decades to capture the mechanics and plasticity behavior of materials. While some UQ studies have been performed, the robustness and uncertainty of these constitutive models have not been rigorously established. In this work, we apply a stochastic collocation (SC) method, which is mathematically rigorous and has been widely used in the field of UQ, to quantify the uncertainty of three most commonly used constitutive models in CPFEM, namely phenomenological models (with and without twinning), and dislocation-density-based constitutive models, for three different types of crystal structures, namely face-centered cubic (fcc) copper (Cu), body-centered cubic (bcc) tungsten (W), and hexagonal close packing (hcp) magnesium (Mg). Our numerical results not only quantify the uncertainty of these constitutive models in stress-strain curve, but also analyze the global sensitivity of the underlying constitutive parameters with respect to the initial yield behavior, which may be helpful for robust constitutive model calibration works in the future.

36 MATERIALS SCIENCE↗

High-throughput, super-resolution 3D reconstruction of nano-structured solid oxide fuel cell electrodes and quantification of microstructure-property relationships

Nano-structuring methods are actively applied to solid oxide fuel cell electrodes to reduce the operating temperature while preserving a high electro-catalytic activity. The unique nanoscale microstructure is vital to electrochemical performance, yet not well quantified in three dimensions. Here, with a multi-stage recovering principle of distance correlation functions, the three-dimensional microstructures of La 0.8 Sr 0.2 MnO 3-δ nanoparticles infiltrated porous Y 0.16 Zr 0.84 O 2-δ electrodes are reconstructed with a dimension of 1024 × 1024 × 1024 voxels at a resolution of 7.5 nm from one two-dimensional micrograph. The key geometric characteristics, such as tortuosity factors, active surface/interface areas and three-phase boundary length, are calculated from the reconstructed three-dimensional microstructures at various loadings of La 0.8 Sr 0.2 MnO 3-δ . Combining with the analysis of distribution of relaxation times, the active three-phase boundary length is shown to be the main factor governing the electrode impedance, and is related quantitatively to the electrochemical process at high frequency. The accuracy of capturing nanoscale features is validated by the focused ion beam sectioning dataset of a Ni-Y 0.16 Zr 0.84 O 2-δ electrode at nanoscale resolution. Lastly, this work provides a promising strategy for reconstructing three-dimensional heterogeneous nanostructures from one super-resolution two-dimensional micrograph, and demonstrates a quantitative approach for uncovering processing-structure-property relationships of nanostructured electrodes and beyond.

25 ENERGY STORAGE↗

Artificial intelligence inferred microstructural properties from voltage–capacity curves

Abstract The quantification of microstructural properties to optimize battery design and performance, to maintain product quality, or to track the degradation of LIBs remains expensive and slow when performed through currently used characterization approaches. In this paper, a convolution neural network-based deep learning approach (CNN) is reported to infer electrode microstructural properties from the inexpensive, easy to measure cell voltage versus capacity data. The developed framework combines two CNN models to balance the bias and variance of the overall predictions. As an example application, the method was demonstrated against porous electrode theory-generated voltage versus capacity plots. For the graphite|LiMn $$_2$$ 2 O $$_4$$ 4 chemistry, each voltage curve was parameterized as a function of the cathode microstructure tortuosity and area density, delivering CNN predictions of Bruggeman’s exponent and shape factor with 0.97 $$R^2$$ R 2 score within 2 s each, enabling to distinguish between different types of particle morphologies, anisotropies, and particle alignments. The developed neural network model can readily accelerate the processing-properties-performance and degradation characteristics of the existing and emerging LIB chemistries.

25 ENERGY STORAGE↗

Abstract for CRADA between the National Energy Technology Laboratory and General Motors (AGMT-0876)

Lightweight aluminum shape castings have widespread applications for structural components in the automotive, aerospace, and general engineering industries because of their excellent castability, corrosion resistance, and particularly high strength-to-weight ratio in the heat-treated condition. In the automotive industry, cast aluminum alloys have been increasingly used to replace cast iron and steel in vehicle applications such as engine blocks, cylinder heads, intake manifolds, brackets, housings, chassis, transmission parts, and suspension systems to reduce mass. As many of the aluminum shape castings used in automobiles involve cyclic loading, fatigue properties of the castings are critical to their success. The increasing use of lightweight aluminum cast components in critical structures thus requires improved integrity, with more reliable and quantifiable performance. The objective of this project is to demonstrate and further develop GM’s patent-pending, novel casting process, “Pressure-Assistant Precision Sand Casting (PAPSC) for producing flawless cast aluminum cylinder heads with minimum manufacturing and energy costs”. The approach is to leverage NETL’s experience in producing high-quality metal castings through various microstructure control and defect elimination technologies as well as comprehensive quantification of microstructure characteristics and mechanical properties. A baseline (production) alloy together with the melt treatment will be initially evaluated with the new PAPSC process to develop and validate the process window for producing flawless cast aluminum heads.

36 MATERIALS SCIENCE↗

Data-driven high-fidelity 2D microstructure reconstruction via non-local patch-based image inpainting

Microstructure reconstruction problems are usually limited to the representation with finitely many number of phases, e.g. binary and ternary. However, images of microstructure obtained through experimental, for example, using microscope, are often represented as a RGB or grayscale image. Because the phase-based representation is discrete, more rigid, and provides less flexibility in modeling the microstructure, as compared to RGB or grayscale image, there is a loss of information in the conversion. In this paper, a microstructure reconstruction method, which produces images at the fidelity of experimental microscopy, i.e. RGB or grayscale image, is proposed without introducing any physics-based microstructure descriptor. Furthermore, the image texture is preserved and the microstructure image is represented with continuous variables (as in RGB or grayscale images), instead of binary or categorical variables, which results in a high-fidelity image of microstructure reconstruction. The advantage of the proposed method is its quality of reconstruction, which can be applied to any other binary or multiphase 2D microstructure. The proposed method can be thought of as a subsampling approach to expand the microstructure dataset, while preserving its image texture. Moreover, the size of the reconstructed image is more flexible, compared to other machine learning microstructure reconstruction method, where the size must be fixed beforehand. In addition, the proposed method is capable of joining the microstructure images taken at different locations to reconstruct a larger microstructure image. A significant advantage of the proposed method is to remedy the data scarcity problem in materials science, where experimental data is scare and hard to obtain. The proposed method can also be applied to generate statistically equivalent microstructures, which has a strong implication in microstructure-related uncertainty quantification applications. The proposed microstructure reconstruction method is demonstrated with the UltraHigh Carbon Steel micrograph DataBase (UHCSDB).

97 MATHEMATICS AND COMPUTING↗

Part-scale evolution of fine-scale microstructural heterogeneity in solid-state additive manufacturing

Current solid-state additive manufacturing methods, refined through costly and time-consuming trial and error, have spurred interest in computational models that replicate material behavior under typical thermomechanical conditions (e.g., strain-rate ~ 102 s−1). These models, however, struggle to capture time-dependent microstructural evolution. In this work, Additive Friction-Stir Deposition (AFSD) is used as a representative case study for part-scale quantification of microstructure evolution at a fine spatial resolution (200 μm) by examining a liquid-nitrogen-cooled stop-action build via energy-dispersive X-ray diffraction coupled with a multi-channel detector. These results inform modeling efforts by linking process asymmetry to stored plastic strain, residual elastic strain, and texture development, and unlike current state-of-the-art characterization methods (e.g., EBSD or neutron diffraction), this approach provides both the spatial resolution and collection efficiency necessary to quantify fine-scale microstructural heterogeneity over large component volumes. As such, this technique provides essential validation data for computational models, e.g., crystal plasticity, enabling future prediction of heterogeneous behavior in AFSD and other additive manufacturing processes.

Franz, Cole [ORNL] (ORCID:0000000213465881)↗

Failure analysis of solid oxide fuel cells nickel-yttria stabilized zirconia anode under siloxane contamination

In this study, the failure process of the solid oxide fuel cell (SOFC) Ni-yttria-stabilized zirconia (YSZ) anode is investigated with D4 siloxane (octamethylcyclotetrasiloxane) contamination. In order to evaluate the influence of the electrochemical reaction on the siloxane deposition process, the SOFC experiments were operated at open circuit voltage (OCV) and 50 mA cm -2 conditions at 800°C. During the failure process, electrochemical, morphology and exhaust gas component analysis testing are conducted at the critical points. An equivalent circuit model and corresponding microstructure parameter calculations for separated physicochemical processes were utilized for the quantitative analysis of the failure process. Further, the results confirm the siloxane chemical adsorption deposition mechanism proposed in previous work. As a result, the failure of the anode was attributed to the gas diffusion blockage by dense silicon dioxide layer formation. The anode failure process with siloxane contamination is faster when the anode is operated under polarization.

25 ENERGY STORAGE↗

Comparing non-destructive 3D X-ray computed tomography with destructive optical microscopy for microstructural characterization of fiber reinforced composites

Due to their lightweight, relatively high stiffness properties, and formability into complex shapes, discontinuous fiber composites are advantageous for producing small and medium size components. Improved characterization techniques and post-processing methodologies are required for more reliable quantification of the microstructure and defect distributions in these materials, in order to employ model-based approaches to assess their structural integrity. This work compares a non-destructive X-ray approach with a destructive optical microscopy approach for characterizing the microstructural attributes, specifically the fiber volume fraction, porosity volume fraction, fiber orientation distribution, and fiber length distribution of discontinuous glass fibers in a polypropylene matrix. Additionally, a method for destructively determining the ambiguous components of the orientation tensor (related to the sign ambiguity of the out-of-plane angle in a destructive cross-sectional cut of a fiber) over a large surface area is included. It was found that fiber volume fraction and average fiber aspect ratio matched well, while fiber orientation and porosity detection had small but notable differences. The differences in the detection capabilities of each technique are quantified and discussed shedding light on the specific advantages and disadvantages of each approach, and enabling engineers to quantify uncertainty in their microstructural characterization measurements especially as they relate to model based structural integrity activities.

Non-destructive testing↗

Quantification of High-Temperature Transition Al2O3 and Their Phase Transformations

High temperature exposure of ?-Al2O3 can lead to a series of polymorphic transformations, including the formation of ?-Al2O3 and ?-Al2O3. Quantification of the microstructure in the ?/?-Al2O3 formation range represents a formidable challenge as both phases accommodate a high degree of structural disorder. In this work, we explore the use of XRD recursive stacking formalism for quantification of high temperature transition aluminas. We formulate the recursive stacking methodology for modelling of disorder in ?-Al2O3 and twinning in ?-Al2O3 and show that explicitly accounting for the disorder is necessary to reliably model the XRD patterns of high temperature transition alumina. In the second part, we use the recursive stacking approach to study phase transformation during high temperature (1050 ºC) treatment. We show that the two different intergrowth modes of ?-Al2O3 have different transformation characteristics, and that a significant portion of ?-Al2O3 is stabilized with ?-Al2O3 even after prolonged high-temperature exposures. In discussions, we outline the limitation of the current XRD approach and discuss a possible multimodal XRD and NMR approach which can improve analysis of complex transition aluminas. This work was performed in the Wiley Environmental Molecular Sciences Laboratory (EMSL), a national scientific user facility sponsored by DOEs Office of Biological and Environmental Research and located at PNNL. The work was supported by the U.S. Department of Energy (DOE), Office of Basic Energy Sciences, Division of Chemical Sciences, Geosciences, and Biosciences.

Kovarik, Libor↗

ML-based Micro-CT SOFC Microstructure Models (from Kent 2026 Microstructural Augmentation paper)

Overview -------------------------- This repository contains datasets from the manuscript **"Enhanced Generalizability to Deep-Learning Quantification of 3D Microstructural Characteristics through Microstructurally Aware Augmentation of Scarce Data"** (*William F. Kent, Rochan Bajpai, Rachel C. Kurchin, William K. Epting, Harry W. Abernathy, Paul A. Salvador. Submitted 2026*). The methods are also described in the dissertation **Data Intensive Analysis of Solid Oxide Cell Microstructures** (*Doctoral dissertation, Carnegie Mellon University, 2025*). The datasets here are trained convolutional neural network (CNN) models for predicting key microstructural properties of solid oxide cell (SOC) electrodes from low-res, 2-channel 3D images, as well as some helpful code. The parameters for input images are provided in the paper. Sample data is provided in the file `Combined_anode_aug_dual_1k_examples` - that particular data was used to train `anode_all_aug.pth` and will work most accurately with that model. Please familiarize yourself with all caveats on accuracy and applicability, as detailed in the associated paper. Usage -------------------------- The basic usage is as follows, assuming `model_fn` is the path to the .pth file, and `X` is 2-channel input image(s) of the proper dimensions (either one image of shape `[2,12,24,24]`, or a batch of N input images of shape `[N,2,12,24,24]`): from CNN_inferencer import load_model_for_inference model = load_model_for_inference(model_fn) y_predicted = model(X) The model object automatically handles input scaling and output de-scaling based on the way the models were trained - in other words, pass in a 2-channel micro-CT image, and it will output microstructural property values in real units. ## Other model object attributes Note that model has useful attributes other than its forward pass model(X). * `model.output_descaler` - returns the output descaler object. Model does the de-scaling when generating inferences, but you may want to re-use this de-scaler on other values to e.g. compare predictions to ground truth from already-scaled training data. * `model.prop_names` - Gives the property names of the predicted y values, in order. Only exists if there's an output scaler as part of the model object, which there will be in the models provided here. ## Usage with sample data Here is a short script to use with the included sample data. from CNN_inferencer import display_predictions, load_model_for_inference, calculate_mape, parity_plot import h5py import numpy as np model_fn = 'anode_all_aug.pth' data_fn = 'Combined_anode_aug_dual_1k_examples.h5' N_samples = 200 figure_outdir = '.' model = load_model_for_inference(model_fn) with h5py.File(data_fn,'r') as f: XX = f['X'] #These are the 2-channel 3D images yy = f['y'] #These are the ground-truth microstructural properties, but they have been scaled for training - need to de-scale below N = XX.shape[0] #How many images total in the input data file #Run inferences on N_samples random samples from XX. #Run in a batch, much more efficient than one at a time. ii = np.random.choice(N,N_samples,replace=False) ii.sort() y_pred = model(XX[ii]) #Get the original/true (but normalized/scaled) values from the training dataset... #Because they were normalized, they are not in real units yet. So let's also de-scale them using model.output_scaler. y_true = model.output_scaler.transform(yy[ii]) #Let's display actual values for just 5 random ones for i in np.random.choice(N_samples,5,replace=False): display_predictions(y_true[i], y_pred[i], model.prop_names) #Make parity plots for each property (ground truth vs predicted values) #Also label each plot with the mean abs. percent error (MAPE) of the predicted values for i,key in enumerate(model.prop_names): mape = calculate_mape(y_true[:,i], y_pred[:,i]) parity_plot(y_true[:,i], y_pred[:,i], figure_outdir, key, extra_title=f' ({mape:.2f}% MAPE)')

3D microstructure↗

Quantification of complex-phase steel microstructure by using combined EBSD and EPMA measurements

Highlights: • In CP800 steel, bainite is the dominant phase with a typical lath (width 300 nm) structure and cementite precipitates. • Martensite is dispersed as small islands and only a few narrowed martensite bands are observed which has been induced by annealing process of cold rolled sheet. • The precise carbon content is measured in bainite and martensite utilizing EPMA line scans, which is around 0.2 wt% and 0.4 wt%, respectively. • Digitalization of the microstructure for CP800 is achieved by combining EBSD and EPMA techniques. • The final constituent map consists of plenty of microstructural features including topography, crystal structures, orientations and elemental distribution. - Abstract: We combined electron backscatter diffraction (EBSD) and electron probe microanalysis (EPMA) techniques to characterize the microstructure of industrial produced complex-phase CP800 steel. First, three major constituents (ferrite, martensite and bainite) are characterized. Then, transformation-induced dislocation zones in ferrite and bainitic regions consisting of different sub-structures are quantified and segmented. A final digitalized component map including plenty of microstructural features including crystal structures, orientations and elemental distribution are successfully achieved. The precise carbon content is measured in bainite and martensite utilizing EPMA line scans, which is around 0.2 wt% and 0.4 wt%, respectively. In the bainite phase of CP800, a typical Bagaryatski orientation relationship between cementite and lath-like bainitic ferrite is revealed based on the select diffraction patterns of transmission electron microscopy measurements.

36 MATERIALS SCIENCE↗

Quantification of solution annealing effects on microstructure and property in a laser powder bed fusion 316H stainless steel

Solution annealing (SA) is an effective way to mitigate microstructural heterogeneity and to optimize mechanical performance of alloys manufactured by laser powder bed fusion (LPBF). In this study, a comprehensive and quantitative understanding of the recovery and recrystallization processes in the SA temperature range of LPBF 316H stainless steel is provided using results from analytical electron microscopy and in-situ high-energy synchrotron x-ray scattering. The profound effect of dislocation structures and secondary phase particles on mechanical performance, particularly under tension and creep conditions, is rationalized using deformation models that incorporate microstructural inputs. This study, for the first time, quantifies the broad effect of nano oxide inclusions on dislocation recovery kinetics, on grain growth and recrystallization kinetics, and on tension strength and creep resistance. The fundamental differences between the LPBF and the conventional wrought materials are revealed. The findings address critical questions in post-build processing of AM materials and pave the way for their rapid qualification for high temperature applications.

In-situ X-ray diffraction↗

Towards inverse microstructure-centered materials design using generative phase-field modeling and deep variational autoencoders

The field of Integrated Computational Materials Engineering (ICME) combines a broad range of methods to study materials’ responses over a spectrum of length scales. A relatively unexplored aspect of microstructure-sensitive materials design is uncertainty propagation and quantification (UP/UQ) of materials’ microstructure, as well as establishing process-structure–property (PSP) relationships for inverse material design. In this study, an efficient UP technique built on the idea of changing probability measures and a deep generative unsupervised representative machine learning method for microstructure-based design of thermal conductivity of materials is proposed. Probability measures are used to represent microstructure space, and Wasserstein metrics are used to test the efficiency of the UP method. By using deep Variational AutoEncoder (VAE), we identify the correlations between the material/process parameters and the thermal conductivity of heterogeneous dual-phase microstructures. Through high-throughput screening, UP, and the deep-generative VAE method, PSP relationships that are too complex can be revealed by exploiting the materials’ design space with an emphasis on microstructures. As a last point, we demonstrate generative machine learning serves as a useful tool for inverse microstructure-centered materials design, and we demonstrate this by examining the inverse design of thermal conductivity in nano-structured materials. Here, the results reveal the effects of morphology, volume fraction, characteristic length scale, and the individual thermal diffusivity of phases on the thermal conductivity of dual-phase alloys. Our findings emphasize the advantages of high-throughput phase-field modeling and generative deep learning for linking PSP and inverse microstructure-centered materials design.

36 MATERIALS SCIENCE↗

High-throughput experimentation for microstructural design in additively manufactured 316L stainless steel

In the present study, a combination of high-throughput (HT) and low-throughput (LT) techniques was used to rapidly determine the processing window and generate processing maps for Selective Laser Melting (SLM) of 316L stainless steel. The HT method includes the fabrication of hundreds of hex nut-shaped specimens, each processed with a unique combination of laser power, scanning speed, and hatch spacing. An easily removable scaffolding permitted rapid sample extraction from the base plate, thus saving machining cost and time. Hardness and immersion density measurements were used for HT characterization to identify a processing window for maximum strength and density. Within the defined processing window, a low-throughput (LT) microstructural interrogation of specimens were performed. The microstructural analysis included quantification at various length scales (i.e., grains size and morphology, texture, primary dendrite arm spacing, and melt pool geometry analysis). Microstructure-based processing maps as a function of volumetric energy density were generated. The combination of HT and LT methods produced a predictive relationship between hardness and primary dendrite arm spacing using a Hall-Petch relationship. A model is proposed to explain the dependence of microstructure on the melt pool geometry. Here, the HT method can be applied for the microstructural design of SLM-fabricated components in other alloys.

316L stainless steel↗

Phase quantification in low carbon Nb-Mo bearing steel by electron backscatter diffraction technique coupled with kernel average misorientation

Highlights: • The microstructures in a low carbon Nb-Mo bearing steel have been investigated. • EBSD combined with a (KAM) map has been used for quantification. • The effects of step size and kernel size on quantification are systemically discussed. • The result indicates that the kernel size should be close to the sub-structure of the granular bainite. - Abstract: An efficient and accurate method is developed for microstructural quantification of complex phases in a low carbon Nb-Mo bearing steel, of which optical micrographs show that it consists of granular bainite and a small amount of ferrite. Our previous work, proposing a method to measure the misorientation angles via electron backscatter diffraction (EBSD) to differentiate granular bainite and ferrite, has been reported. That method is accurate for phase quantification but laborious for the characterization process. To resolve this difficulty, in this study, EBSD combined with a kernel average misorientation (KAM) map is used for phase characterization. Comparisons are made among KAM maps with different kernel sizes (300 to 600 nm) and various step sizes (100 to 600 nm). It is found that a kernel size close to the sub-structure size of granular bainite (500 nm) is optimal for phase identification, while varied step sizes produce relatively invariant results. Therefore, KAM maps can be used for fast and reliable phase quantification, provided that an appropriate kernel size and a large step size are used.

36 MATERIALS SCIENCE↗