Organizations: School of Artificial Intelligence, University of Science and Technology Beijing, China · School of Materials Science and Engineering, University of Science and Technology Beijing, China · School of Big Data and Software Engineering, Chongqing University, China · China Telecom Artificial Intelligence Technology (Beijing) Co., Ltd · School of Advanced Materials Innovation, University of Science and Technology Beijing, China · Institute of Materials Intelligent Technology, Liaoning Academy of Materials, China
Zinc-based alloys are indispensable emerging absorbable metallic biomaterials, and their macroscopic performance is governed by microstructural characteristics. Intermediate phases-key microstructural constituents-are pivotal in regulating mechanical and functional properties. However, intermediate phase segmentation in zinc alloy microstructures faces formidable challenges: scarce annotated datasets, low contrast, difficulty detecting small targets, and heterogeneous morphologies. To this end, we construct IPSM-Bench, the largest high-quality dataset for zinc-alloy intermediate phase segmentation. Furthermore, we propose SCoP-SAM, a new Spatial Context Prior-guided SAM method that leverages the gradient structure and grayscale properties of intermediate phases to capture spatial context priors and incorporates them into the entire SAM encoding-decoding process, improving segmentation performance. Based on the proposed IPSM-Bench, we establish a new benchmark for intermediate phase segmentation to systematically evaluate state-of-the-art (SOTA) methods and advance research on zinc alloy microstructure analysis. Extensive experiments on IPSM-Bench and additional public alloy benchmarks demonstrate that our SCoP-SAM not only achieves SOTA performance for zinc-alloy intermediate phase segmentation but also generalizes remarkably well to other alloy scenarios.
The performance of advanced materials for extreme environments is underpinned by their microstructure, including the size and distribution of reinforcing phases. Chromium-based superalloys are a recently proposed alternative to conventional face-centred-cubic superalloys for high-temperature applications, such as Concentrated Solar Power, and their development requires efficient measurement of precipitate volume fraction and size distribution from electron microscopy images. Traditional fixed-threshold image processing is sensitive to background noise, generalises poorly across materials, and requires substantial manual measurement effort. To address these bottlenecks, this study proposes DT-SegNet, an end-to-end two-stage deep learning scheme based on YOLOv5 and SegFormer for object detection and segmentation in electron microscopy images. The approach combines the training efficiency of convolutional neural networks at the detection stage with the segmentation accuracy of a Vision Transformer. Numerical experiments show that DT-SegNet substantially outperforms state-of-the-art segmentation tools offered by Weka and ilastik across metrics including accuracy, precision, recall, and F1-score. The model provides a useful tool for alloy-development microstructure examinations and helps address the large datasets associated with high-throughput alloy development.
X-ray tomography enables nondestructive characterization of material microstructures, while advances in micro-CT imaging have accelerated volumetric data acquisition and reconstruction. However, rapid interpretation remains limited by image segmentation, which often requires manual thresholding, user prompting, or material-specific model training. We present a zero-setup framework for multi-phase segmentation of synchrotron X-ray tomography data that generates interpretable masks for previously unseen datasets without user input or retraining during deployment. The framework combines a material-agnostic mask preparation strategy with a pretrained semantic segmentation network. It represents commonly occurring structural regions as background, sample, bright, dark-gray, light-gray, and porosity masks. Unlike conventional deep learning pipelines that require dataset-specific annotations and retraining, the proposed framework can be applied directly to new scans and produce diagnostic-level segmentations within minutes of reconstruction. This enables rapid assessment of scan quality, sample morphology, porosity, and attenuation variations during ongoing beamline experiments. The generated masks can later be manually refined or used to fine-tune application-specific models when greater accuracy or material-specific labeling is required. Evaluation on held-out synchrotron micro-CT images and qualitative testing on additional datasets demonstrate consistent and physically meaningful segmentations across varying samples and imaging conditions. The framework also substantially outperforms conventional intensity-based thresholding. By connecting high-speed reconstruction with immediate interpretation, the approach supports near-real-time beamline feedback and scalable AI-assisted scientific imaging workflows.
Pradyumna Elavarthi, Arun J. Bhattacharjee, Harrison Lisabeth +4
Extracting standardized metallurgical metrics from microscopy images remains challenging due to complex grain morphology and the data demands of supervised segmentation. To bridge foundational computer vision with practical metallurgical evaluation, we propose an automated pipeline for dense instance segmentation and grain size estimation that adapts Cellpose-SAM to microstructures and integrates its topology-aware gradient tracking with an ASTM E112 Jeffries planimetric module. We systematically benchmark this pipeline against a classical convolutional network (U-Net), an adaptive-prompting vision foundation model (MatSAM) and a contemporary vision-language model (Qwen2.5-VL-7B). Our evaluations reveal that while the out-of-the-box vision-language model struggles with the localized spatial reasoning required for dense microscopic counting and MatSAM suffers from over-segmentation despite its domain-specific prompt generation, our adapted pipeline successfully maintains topological separation. Furthermore, experiments across progressively reduced training splits demonstrate exceptional few-shot scalability; utilizing only two training samples, the proposed system predicts the ASTM grain size number (G) with a mean absolute percentage error (MAPE) as low as 1.50%, while robustness testing across varying target grain counts empirically validates the ASTM 50-grain sampling minimum. These results highlight the efficacy of application-level foundation model integration for highly accurate, automated materials characterization. Our project repository is available at https://github.com/mueez-overflow/ASTM-Grain-Size-Estimator.