New computational approach solves critical challenge in additive manufacturing materials design

7/7/2025

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Ivan Racheff Professor Dallas Trinkle from the Department of Materials Science and Engineering at The Grainger College of Engineering, University of Illinois Urbana-Champaign, has received an Editors' Suggestion designation from Physical Review Materials for his paper "Computing ternary liquid phase diagrams: Fe-Cu-Ni."

Why it matters

The Editors' Suggestion recognition places Trinkle's work among a select group of papers that editors and referees find of particular interest, importance, or clarity. Physical Review Materials formally lists only a small number of papers for this honor, which will feature prominently on the journal's website with an image and author-written summary. This computational breakthrough addresses a significant challenge in materials science: accurately determining phase diagrams for liquid immiscible systems that hold promise for additive manufacturing applications.

Ivan Racheff Professor Dallas Trinkle
Ivan Racheff Professor Dallas Trinkle

The big picture

Trinkle's research introduces a virtual semigrand canonical Widom approach that efficiently computes differences in excess chemical potentials between different species in metal alloys, specifically mapping the complex phase behavior of Fe-Cu-Ni ternary liquids. The method represents a significant advancement in computational materials science by providing accurate phase diagrams, miscibility gaps, and spinodal decompositions with computational costs similar to the trajectory calculation itself.

  • The technique can be applied as a post-processing step with regular molecular dynamics or Monte Carlo simulations for both solids and liquids.
  • The research addresses critical needs in additive manufacturing, where Fe-Cu liquid immiscible systems offer exciting possibilities but present phase diagram determination challenges.
  • Trinkle’s method uses an embedded atom potential for Fe-Cu-Ni to simulate liquid states over a range of compositions and temperatures, then fits this data to Redlich-Kister polynomials for the Gibbs free energy with simple temperature dependence.
  • The approach demonstrates remarkable precision, with absolute Gibbs free energy calculations accurate to within 1 meV for ternary systems.

The work also includes comprehensive validation through static structure factors (using the S₀ method to estimate the second derivative of the Gibbs free energy) and nonequilibrium Hamiltonian integration methods to compute absolute Gibbs free energies for pure liquid states, establishing the reliability of the computational framework for predicting density variations and pair correlation functions across different compositions and temperatures.

"This computational approach opens new pathways for understanding complex metal alloy behavior in liquid states, which is crucial for advancing additive manufacturing technologies," Trinkle explained regarding the broader implications of the research.

The Editors' Suggestion designation underscores the significance of Trinkle's contribution to computational materials science and highlights Illinois Grainger Engineering's continued leadership in developing innovative approaches to materials research challenges.

Illinois Grainger Engineering Affiliations 

Dallas Trinkle is an Ivan Racheff Professor in materials science and engineering at The Grainger College of Engineering. He is affiliated with the Materials Research Laboratory. Trinkle serves as Associate Head of Undergraduate Studies for the materials department. 


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This story was published July 7, 2025.