Mapping Microstructure: Manifold Construction for Accelerated Materials Exploration

Abstract Accelerating materials development requires quantitative linkages between processing, microstructure, and properties. In this work, we introduce a framework for mapping microstructure onto a low-dimensional material manifold that is parametrized by processing conditions. A key innovation is treating microstructure as a stochastic process, defined as a distribution of microstructural instances rather than a single image, enabling the extraction of material state descriptors that capture the essential process-dependent features. We leverage the manifold hypothesis to assert that microstructural outcomes lie on a low-dimensional latent space controlled by only a few parameters. Using phase-field simulations of spinodal decomposition as a model material system, we compare multiple microstructure descriptors (two-point statistics, chord-length distributions, and persistent homology) in terms of two criteria: (1) intrinsic dimensionality of the latent space, and (2) invertibility of the processing-to-structure mapping. The results demonstrate that distribution-based descriptors can recover a two-dimensional latent structure aligned with the true processing parameters, yielding an invertible and physically interpretable mapping between processing and microstructure. In contrast, descriptors that do not account for microstructure variability either overestimate dimensionality or lose predictive fidelity. The constructed material manifold is shown to be locally continuous, wherein small changes in process variables correspond to smooth changes in microstructure descriptors. This data-driven manifold mapping approach provides a quantitative foundation for microstructure-informed process design and paves the way toward closed-loop optimization of processing–structure–property relationships in an integrated materials engineering context.