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Automated grain analysis via data augmentation and grain boundary detection.

Zhihao Gao1, Yintao Zhou2

  • 1School of Jiluan Academy, Nanchang University, Nanchang, 330031, China.

Micron (Oxford, England : 1993)
|November 25, 2025
PubMed
Summary

This study introduces an AI framework for quantitative metallographic analysis of pure iron. It overcomes data scarcity and manual analysis limitations using advanced data synthesis and deep learning for accurate grain size characterization.

Keywords:
Automated grain analysisBoundary detectionData augmentationDeep learning

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Area of Science:

  • Materials Science
  • Artificial Intelligence
  • Computational Methods

Background:

  • Manual grain size analysis in pure iron is inefficient and lacks reproducibility.
  • Existing computational methods struggle with limited data and incomplete grain boundary detection.

Purpose of the Study:

  • To develop an AI-enhanced framework for quantitative metallographic analysis of pure iron.
  • To address challenges of data scarcity and subjectivity in current methods.

Main Methods:

  • A three-stage data synthesis pipeline using denoising diffusion probabilistic models (DDPM) and conditional adversarial networks.
  • Training a U-Net based deep neural network on a paired and reconstructed dataset for topology-aware analysis.
  • Establishing an automated grain analysis system with whole-grain area quantification and twin-grain merging.

Main Results:

  • Generated physically consistent metallographic images through advanced data synthesis.
  • Achieved topology-awareness in grain analysis via data pairing and reconstruction objectives.
  • Developed a fully automated system resolving limitations in data scarcity and manual evaluation subjectivity.

Conclusions:

  • The AI-enhanced framework significantly improves quantitative metallographic analysis of pure iron.
  • The methodology offers a robust solution for data scarcity and subjectivity issues.
  • Enables more efficient and reproducible grain size characterization.