| Abstract Scope |
Accelerating materials discovery for extreme environments requires high-throughput experimentation and in-situ alloy design strategies guiding researchers toward processable, high-performance compositions. Cracking has remained a critical challenge in the additive manufacturing (AM) of Ni- and Co-based superalloys, limiting their deployment in such applications. In this work, we investigate crack formation during directed energy deposition (DED) of conventional Ni- and Co-based superalloys and employ data-driven methods to design AM-compatible alloys with enhanced high-temperature performance. A CALPHAD-guided framework was used to identify promising chemistries, which were fabricated and rapidly screened using high-throughput DED processing. Post-process characterization, including microstructural analysis and high-temperature wear testing, was conducted to assess crack susceptibility and mechanical behavior. Our integrated strategy enabled the discovery of Ni- and Co-based alloys that were both printable and resistant to cracking and degradation at elevated temperatures, providing a foundation for the design of next-generation superalloys tailored for additive manufacturing in extreme service conditions. |