Deep Learning–Assisted Material Design and Laser Direct Additive Manufacturing of a Metal Ceramic Composite that Transforms into Ceramic at High Temperatures

A new Hf-Zr-C-based metal ceramic composite capable of transforming into a ceramic at high temperatures was developed using deep learning (DL)–assisted materials design, with screening performed across approximately 20 million compositions. Components were directly fabricated from mixed powders by laser powder bed fusion (LPBF). The as-fabricated material exhibited high fracture toughness (6.32 MPa·m 1/2 ), low thermal conductivity (6.34 W·m –1 ·K –1 ), and good room-temperature machinability, properties not achievable in traditional carbides. At elevated temperatures, the material transformed into a single-phase ceramic through solid-phase diffusion, with a measured melting point of (4181 ± 85) K. This study demonstrates a viable route for the design and direct additive manufacturing of refractory ceramic components from multi-powder systems.