KAIST

<Picture1.(From Left) Prof. Seungbum Hong, Ph.D candidate Youngwoo Choi>

Steel alloys used in automobiles and machinery parts are typically manufactured through a melting process at high temperatures. The phenomenon where the components remain unchanged during melting is called “congruent melting.” KAIST researchers have now addressed this process—traditionally only possible through high-temperature experiments—using artificial intelligence (AI). This study draws attention as it proposes a new direction for future alloy development by predicting in advance how well alloy components will mix during melting, a long-standing challenge in the field.

KAIST (President Kwang Hyung Lee) announced on the 14th of July that Professor Seungbum Hong’s research team from the Department of Materials Science and Engineering, in international collaboration with Professor Chris Wolverton’s group at Northwestern University, has developed a high-accuracy machine learning model that predicts whether alloy components will remain stable during melting. This was achieved using formation energy data derived from Density Functional Theory (DFT)* calculations.
 *Density Functional Theory (DFT): A computational quantum mechanical method used to investigate the electronic structure of many-body systems, especially atoms, molecules, and solids, based on electron density.

The research team combined formation energy values obtained via DFT with experimental melting reaction data to train a machine learning model on 4,536 binary compounds.

Among the various machine learning algorithms tested, the XGBoost-based classification model demonstrated the highest accuracy in predicting whether alloys would mix well, achieving a prediction accuracy of approximately 82.5%. The team also applied the Shapley value method* to analyze the key features of the model. One major finding was that sharp changes in the slope of the formation energy curve (referred to as “convex hull sharpness”) were the most significant factor. A steep slope indicates a composition with energetically favorable (i.e., stable) formation.
 *Shapley value: An explainability method in AI used to determine how much each feature contributed to a prediction.

The most notable significance of this study is that it predicts alloy melting behavior without performing high-temperature experiments. This is especially useful for materials such as high-entropy alloys or ultra-heat-resistant alloys, which are difficult to handle experimentally. The approach could also be extended to the design of complex multi-component alloy systems in the future.

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Furthermore, the physical indicators identified by the AI model showed high consistency with actual experimental results on how well alloys mix and remain stable. This suggests that the model could be broadly applied to the development of various metal materials and the prediction of structural stability.

Professor Seungbum Hong of KAIST stated, “This research demonstrates how data-driven predictive materials development is possible by integrating computational methods, experimental data, and machine learning—departing from the traditional experience-based alloy design.” He added, “In the future, by incorporating state-of-the-art AI techniques such as generative models and reinforcement learning, we could enter an era where completely new alloys are designed automatically.”

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<Model performance and feature importance analysis for predicting melting congruency. (a) SHAP summary plot showing the impact of individual features on model predictions. (b) Confusion matrix illustrating the model’s classification performance. (c) Receiver operating characteristic (ROC) curve with an AUC (area under the curve) score of 0.87, indicating a strong classification performance.>

Ph.D. candidate Youngwoo Choi, from the Department of Materials Science and Engineering at KAIST, participated as the first author. The study was published in the May issue of APL Machine Learning, a prestigious journal in the field of machine learning published by the American Institute of Physics, and was selected as a “Featured Article.”

※ Paper title: Machine learning-based melting congruency prediction of binary compounds using density functional theory-calculated formation energy
 ※ DOI: 10.1063/5.0247514

This research was supported by the Ministry of Science and ICT and the National Research Foundation of Korea.