Additively manufacturable high-strength aluminum alloys with thermally stable microstructures enabled by hybrid machine learning-based design

Additively manufactured (AM) aluminum alloys with high strength and thermal stability have broad applications in turbine engines, vacuum pumps, heat exchangers, and many other industrial systems. Employing precipitates with an L1$_2$ structure to block dislocation motions is a widespread strategy to strengthen aluminum. However, to achieve high strength, a high volume fraction of small precipitates is required, and these characteristics are generally mutually exclusive. Here, we show that for certain compositions of Al alloys, L1$_2$ phases initially precipitate as sub-micron metastable ternary phases under the rapid solidification conditions of powder bed AM, yet the subsequent L1$_2$ phases that precipitate during heat treatment of the sample remain at the nanoscale, imparting high strength. For strength to be retained at elevated temperature, these nanoprecipitates must have low coarsening rates. To inversely design the composition of an alloy to have these target microstructural features, we used hybrid calculation of phase diagram (CALPHAD)-based integrated computational materials engineering (ICME) and Bayesian optimization techniques. We tested our approach by designing an Al-Er-Zr-Y-Yb-Ni model alloy, and the selected composition was manufactured in powder form as AM feedstock. The strength of specimens manufactured via laser powder bed fusion (LPBF) from the designed composition is comparable to that of wrought Al 7075, yet without cracking that occurs upon LPBF of Al 7075. After high-temperature (400$^\circ$C) aging the designed alloy is 50% stronger than the strongest known benchmark printable Al alloy.