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<p>Many conventional alloys are poorly suited to laser-based additive manufacturing (also known as 3D printing) because of complex laser-material interactions and thermal histories. Identifying new printable alloys out of vast compositional spaces is a daunting task, particularly for complex concentrated alloys of three or more elements. Here, we integrate active learning with additive manufacturing to accelerate the discovery of NiCoCr complex concentrated alloys via a high-throughput highway. We identify six new printable alloys that are up to ~40% harder than the popular equiatomic NiCoCr at room temperature. Among them, two new alloys exhibit complementary advantages: Ni<sub>12</sub>Co<sub>62</sub>Cr<sub>26</sub> retains ~50% higher hardness than NiCoCr at 600 °C, whereas Ni<sub>36</sub>Co<sub>14</sub>Cr<sub>50</sub> reduces oxidation mass gain by 85% at 1000 °C compared with conventional superalloys. Our study demonstrates that optimum performance can reside far from equiatomic proportions and can be uncovered with substantially fewer experiments when exploration is guided by application-specific objectives. The modular workflow provides a general route to rapidly discover new printable, alloys for targeted demanding service conditions.</p>

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Active learning for the accelerated discovery of complex concentrated NiCoCr alloys in additive manufacturing

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年6月23日

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  • Ajay Talbot,
  • Soumya S. Dash,
  • Jialu Li,
  • Changjun Cheng,
  • Madhi Ramesh,
  • Xiao Shang,
  • Jiahui Zhang,
  • Cristian Cojocaru,
  • Jason Hattrick-Simpers,
  • Yu Zou

摘要

Many conventional alloys are poorly suited to laser-based additive manufacturing (also known as 3D printing) because of complex laser-material interactions and thermal histories. Identifying new printable alloys out of vast compositional spaces is a daunting task, particularly for complex concentrated alloys of three or more elements. Here, we integrate active learning with additive manufacturing to accelerate the discovery of NiCoCr complex concentrated alloys via a high-throughput highway. We identify six new printable alloys that are up to ~40% harder than the popular equiatomic NiCoCr at room temperature. Among them, two new alloys exhibit complementary advantages: Ni12Co62Cr26 retains ~50% higher hardness than NiCoCr at 600 °C, whereas Ni36Co14Cr50 reduces oxidation mass gain by 85% at 1000 °C compared with conventional superalloys. Our study demonstrates that optimum performance can reside far from equiatomic proportions and can be uncovered with substantially fewer experiments when exploration is guided by application-specific objectives. The modular workflow provides a general route to rapidly discover new printable, alloys for targeted demanding service conditions.