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Acta Metall Sin  2021, Vol. 57 Issue (6): 797-810    DOI: 10.11900/0412.1961.2020.00298
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Composition Refinement of 6061 Aluminum Alloy Using Active Machine Learning Model Based on Bayesian Optimization Sampling
ZHAO Wanchen1, ZHENG Chen1, XIAO Bin1, LIU Xing2, LIU Lu1, YU Tongxin1, LIU Yanjie1, DONG Ziqiang1, LIU Yi1(), ZHOU Ce3, WU Hongsheng3, LU Baokun3
1.Materials Genome Institute, Shanghai University, Shanghai 200444, China
2.Qianweichang College, Shanghai University, Shanghai 200444, China
3.Nanping Aluminum Corporation, Nanping 353099, China
Cite this article: 

ZHAO Wanchen, ZHENG Chen, XIAO Bin, LIU Xing, LIU Lu, YU Tongxin, LIU Yanjie, DONG Ziqiang, LIU Yi, ZHOU Ce, WU Hongsheng, LU Baokun. Composition Refinement of 6061 Aluminum Alloy Using Active Machine Learning Model Based on Bayesian Optimization Sampling. Acta Metall Sin, 2021, 57(6): 797-810.

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Abstract  

Within the China standard (6061 GB/T 3190-2008) of the aluminum alloy 6061, there are a wide range of alloy compositions having multiple trace elements. From the viewpoint of scientific research and quality control in industries, it is important to understand the relationship between the different potential compositions and corresponding mechanical properties of the aluminum alloy 6061. In this work, high-throughput experiments on materials synthesis and an active-learning framework based on the Bayesian optimization sampling process were combined to develop effective machine learning (ML) models to describe the relationship between the composition and hardness of aluminum 6061 alloys. In this work, > 100 alloys with ML designed compositions were synthesized and their hardness data were obtained through high-throughput experiments. The composite ML features were introduced by combining elementary material properties and chemical compositions of alloys and were selected subsequently according to their importance and correlation among features. The efficiencies of two sampling strategies were compared in guiding the iterative experiments: manual sampling based on empirical experience and Bayesian optimization sampling trained within the active-learning framework using the efficient global optimization and knowledge gradient algorithms. These ML models were updated iteratively until the prediction accuracy approached the experimental error. Specifically, the error in the hardness values predicted by the Bayesian model using 64 aluminum alloy samples after three rounds of iterations was 4.49 HV (7.23%), which is much lower than the error predicted by the empirical sampling method (9.73 HV; 15.68%). The results show that Bayesian optimization sampling accelerates the optimization of alloys property more efficiently than manual empirical sampling. Finally, the machine learning models using Bayesian sampling were interpreted using the Shapley additive explanations method and analysis of the partial dependence plot discuss the effects of various trace alloying elements and composite ML features on the hardness of the aluminum alloys. It was found that the hardness value of the aluminum alloys became large when the ratio between Mg and Si (Mg/Si) was between 1.37 and 1.72. In addition, the machine learning models suggested that the lattice distortion, cohesive energy, configurational entropy, and shear modulus were positively proportional to the hardness of the alloy. This work demonstrated that active-learning-guided high-throughput experiments on composition refinement can not only improve the performance and quality control of aluminum 6061 alloys within its standard nominal composition range as used in industry but also provide a feasible approach for the design and property optimization of other multialloy materials.

Key words:  machine learning      Bayesian optimization      high-throughput experiment      6061 aluminum alloy      composition refinement     
Received:  13 August 2020     
ZTFLH:  TG146.2  
Fund: National Key Research and Development Program of China(2017YFB0702901)
About author:  LIU Yi, professor, Tel: 18616846006, E-mail: yiliu@shu.edu.cn

URL: 

https://www.ams.org.cn/EN/10.11900/0412.1961.2020.00298     OR     https://www.ams.org.cn/EN/Y2021/V57/I6/797

Fig.1  Active-learning framework of alloy design
Fig.2  Bootstrap random sampling modeling method
Feature indexFeature nameFeature indexFeature name
F_0Ave: electron_affinityF_1Ave: hhi_r
F_2Var: covalent_radiusF_3Sum: atomic_weight
F_4Var: gs_est_fcc_latcntF_5Var: atomic_radius
F_6Modulus mismatchF_7Var: atomic_radius_rahm
F_8Shear modulusF_9Lattice distortion energy
F_10Mixing enthalpyF_11Parameter omiga
F_12Ave: dipole_polarizabilityF_13Sum: c6_gb
F_14Cohesive energyF_15Var: molar_volume
F_16Var: first_ion_enF_17Ave: covalent_radius_pykko_triple
F_18Ave: boiling_pointF_19Sum: heat_of_formation
F_20Configurational entropyF_21Ave: electron_negativity
Table 1  Features indexes and implication of 22 important property features
Fig.3  Pearson correlation feature selection results (Features in black are those selected from five groups with higher feature importance. Features in red are those not selected)
Fig.4  Feature selection method and result comparisons between sequential forward selection (SFS) and sequential backward selection (SBS)
Fig.5  Comparisons among machine learning models
RoundEVSMAE / HVMSE / HVRMSE / HVMedAE / HV
First round-0.1014.60301.8017.310.09
The second round of mME-0.1110.06138.1011.750.04
The second round of mBO0.315.5738.566.210.01
The third round of mME0.167.7994.599.730.03
The third round of mBO0.502.8820.134.49< 0.01
The third round of mBOe-0.064.8542.416.510.01
Table 2  Evaluation results of the regression models
Fig.6  Prediction results of mME and mBO models in the first iteration (sBO—sampling based on BO, sME—sampling based on ME) (a), second iteration (b), third iteration (c), and comparisons of model error RMSE (The error bars are the mean standard deviation of the experiments) (d)
Fig.7  Comparisons between prediction results of mBO and mBOe models
Fig.8  Features importance analyses and relational dependence plots of Mg and Si based on Shapley additive explanations (SHAP)
Fig.9  Absolute influence of trace element features on hardness (blue shade—confidence interval, red line—baseline value)
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