Phase prediction and experimental realisation of a new high entropy alloy using machine learning

Nearly ~ 10⁸ types of High entropy alloys (HEAs) can be developed from about 64 elements in the periodic table. A major challenge for materials scientists and metallurgists at this stage is to predict their crystal structure and, therefore, their mechanical properties to reduce experimental efforts, which are energy and time intensive. Through this paper, we show that it is possible to use machine learning (ML) in this arena for phase prediction to develop novel HEAs. We tested five robust algorithms namely, K-nearest neighbours (KNN), support vector machine (SVM), decision tree classifier (DTC), random forest classifier (RFC) and XGBoost (XGB) in their vanilla form (base models) on a large dataset screened specifically from experimental data concerning HEA fabrication using melting and casting manufacturing methods. This was necessary to avoid the discrepancy inherent with comparing HEAs obtained from different synthesis routes as it causes spurious effects while treating an imbalanced data—an erroneous practice we observed in the reported literature. We found that (i) RFC model predictions were more reliable in contrast to other models and (ii) the synthetic data augmentation is not a neat practice in materials science specially to develop HEAs, where it cannot assure phase information reliably. To substantiate our claim, we compared the vanilla RFC (V-RFC) model for original data (1200 datasets) with SMOTE-Tomek links augmented RFC (ST-RFC) model for the new datasets (1200 original + 192 generated = 1392 datasets). We found that although the ST-RFC model showed a higher average test accuracy of 92%, no significant breakthroughs were observed, when testing the number of correct and incorrect predictions using confusion matrix and ROC-AUC scores for individual phases. Based on our RFC model, we report the development of a new HEA (Ni₂₅Cu_18.75Fe₂₅Co₂₅Al_6.25) exhibiting an FCC phase proving the robustness of our predictions.