Metastable defect phase diagrams as roadmap to tailor chemically driven defect formation

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Thermodynamic bulk phase diagrams have become the roadmap used by researchers to identify alloy compositions and process conditions that result in novel materials with tailored properties. Recent experimental studies show that changes in the alloy composition can drive not only transitions in the bulk phases present in a material, but also in the concentration and type of defects they contain. Defect phase diagrams in combination with density functional theory provide a natural route to study these chemically driven defects. Our results reveal, however, that direct application of equilibrium bulk thermodynamics can fail to reproduce experimentally observed defect formation. Therefore, we extend the concept to metastable defect phase diagrams to account for kinetic limitations that prevent the system from reaching equilibrium. We apply this concept to successfully explain the formation of large concentrations of planar defects in supersaturated Fe-Nb solid solutions. We then utilize it to design suitable conditions for synthesis, which we subsequently realized experimentally, successfully validating the formation of the predicted defects in Mg-Al-Ca alloys. The concept offers new avenues for the design of materials performance by tailoring defect structures.