GeGra: Approaching a generic model for quantitative grain size analysis from materials microscopy data using deep learning

Grain size has a significant impact on the properties of materials, and is crucial for predicting material properties. Traditional grain size measurement relies heavily on human operators, leading to subjective results, and existing machine learning methods are typically material-specific, requiring significant labeling and training efforts for each new material. This paper provides insight into developing a deep learning-based generic grain boundary detection model (GeGra) from different material micrographs. The model is trained on 1006 images from various microscopy techniques such as light optical, Kerr, and scanning electron microscopy, acquired at different magnifications for different materials such as copper, austenite, brass, sintered hard magnet, hard metal, bronze, nickel silver, and aluminum. The developed GeGra model effectively handles visual artifacts and substructures such as twin grains, which often pose challenges for material-specific, state-of-the-art grain boundary segmentation models. The developed model achieved an IoU score of 69 % on a diverse test set and enables accurate grain size analysis using external image analysis software in less than one minute, according to ASTM standards, which is more than 5 times faster than the manual method. The developed model prioritizes generality with objective that it can have broader applicability for various materials instead of high-precision grain boundary detection. Additionally, the model has the potential to be a foundational tool for generalized grain size analysis in material microscopy, reducing the effort required for such analysis and assisting both material science experts and machine learning users. [Display omitted] •GeGra is a generic grain boundary detection model valid across diverse materials.•It overcomes material-specific limitations in ML-assisted automated grain size analysis.•Robust to visual artifacts in microscopy images and substructures within the grains.•Enables automated grain size analysis using third-party software, more than 5× faster than manual methods.•Potential to be a foundational model for materials microscopy tasks specifically for grain boundary detection tasks.