Data-efficient continuous conditional denoising diffusion model for microstructure generation

Traditional computational models, such as cellular automata and phase-field methods, are effective for simulating microstructural evolution but often face computational bottlenecks, limiting their application in high-throughput and on-demand process optimization. Generative machine learning approaches, such as denoising diffusion models, have emerged as powerful tools for surrogate modeling of process-structure maps, specifically producing representative microstructures conditioned on process parameters. However, they often require large amounts of data for training, particularly when process conditions are continuous rather than discrete categorical variables. To address this, we present a continuous conditional denoising diffusion model for generating microstructures conditioned on processing parameters. Trained on a compact dataset of process-microstructure pairs, this framework first adds noise to microstructure images and then trains a neural network to progressively remove the noise, learning the underlying statistical patterns of the microstructure. To address data inefficiencies associated with continuously valued process conditions, we propose a vicinal-loss training strategy that associates process conditions in data-sparse regions with nearby conditions in the dataset. Combined with classifier-free guidance and denoising diffusion implicit sampling, this approach enables data-efficient continuous conditional generation of microstructures compared to classical denoising diffusion models. The model successfully generates representative microstructures for low-carbon steel conditioned on manganese composition, matching key physical features such as phase and grain morphology, grain size distribution, phase fraction, and interfacial area distribution. More generally, this approach opens avenues for efficient process design and optimization of materials and their microstructures.