During powder production, the pre-alloyed powder composition often deviates from the target composition leading to undesirable properties of additive manufacturing (AM) components. Therefore, we developed a method to perform high-throughput calculation and uncertainty quantification by using a CALPHAD-based ICME framework (CALPHAD: calculations of phase diagrams, ICME: integrated computational materials engineering) to optimize the composition, and took the high-strength low-alloy steel (HSLA) as a case study. We analyzed the process–structure–property relationships for 450,000 compositions around the nominal composition of HSLA-115. Properties that are critical for the performance, such as yield strength, impact transition temperature, and weldability, were evaluated to optimize the composition. With the same uncertainty as to the initial composition, and optimized average composition has been determined, which increased the probability of achieving successful AM builds by 44.7%. The present strategy is general and can be applied to other alloy composition optimization to expand the choices of alloy for additive manufacturing. Such a method also calls for high-quality CALPHAD databases and predictive ICME models.

Stacking fault energy (SFE) is of the most critical microstructure attribute for controlling the deformation mechanism and optimizing mechanical properties of austenitic steels, while there are no accurate and straightforward computational tools for modeling it. In this work, we applied both thermodynamic modeling and machine learning to predict the stacking fault energy (SFE) for more than 300 austenitic steels. The comparison indicates a high need of improving low-temperature CALPHAD (CALculation of PHAse Diagrams) databases and interfacial energy prediction to enhance thermodynamic model reliability. The ensembled machine learning algorithms provide a more reliable prediction compared with thermodynamic and empirical models. Based on the statistical analysis of experimental results, only Ni and Fe have a moderate monotonic influence on SFE, while many other elements exhibit a complex effect that their influence on SFE may change with the alloy composition.

Metastable alloys with transformation-/twinning-induced plasticity (TRIP/TWIP) can overcome the strength-ductility trade-off in structural materials. Originated from the development of traditional alloys, the intrinsic stacking fault energy (ISFE) has been applied to tailor TRIP/TWIP in high-entropy alloys (HEAs) but with limited quantitative success. Here, we demonstrate a strategy for designing metastable HEAs and validate its effectiveness by discovering seven alloys with experimentally observed metastability for TRIP/TWIP. We propose unstable fault energies as the more effective design metric and attribute the deformation mechanism of metastable face-centered cubic alloys to unstable martensite fault energy (UMFE)/unstable twin fault energy (UTFE) rather than ISFE. Among the studied HEAs and steels, the traditional ISFE criterion fails in more than half of the cases, while the UMFE/UTFE criterion accurately predicts the deformation mechanisms in all cases. The UMFE/UTFE criterion provides an effective paradigm for developing metastable alloys with TRIP/TWIP for an enhanced strength-ductility synergy.