Microstructure sensitive recurrent neural network surrogate model of crystal plasticity

Abstract: The development of next-generation structural materials for harsh environments requires rapid assessment of mechanical performance and its dependence on microstructure. While full-field crystal plasticity (CP) models provide detailed insights, the high computational cost limits their use with uncertainty quantification workflows and in component-scale simulation. Surrogate models based on recurrent neural networks (RNNs) have shown promise in reproducing history-dependent mechanical behaviour but are applied to models with either fixed microstructure or representative volume elements. Here, we develop a microstructure sensitive RNN surrogate that predicts homogenised stress responses directly from three-dimensional grain structures and arbitrary deformation histories. The architecture employs a gated recurrent unit (GRU) with mappings from microstructure to both the initial hidden state and sequence inputs, allowing the model to capture path dependence and microstructure variability. Training data comprised of over 300,000 CP simulations generated using combinations of randomly generated microstructures and loading paths. The model was found to reproduce CP predictions for both in-distribution validation data and unseen deformation modes, with errors of 2 MPa to 3 MPa. Out-of-distribution microstructures were more difficult to predict, emphasising the need for representative training data with, for example, heavily textured microstructures. Embedding the model into a multiscale framework demonstrates its ability to replace conventional constitutive updates, reducing computational cost while preserving key features of the stress distribution. These results establish microstructure-informed RNN surrogates as a promising alternative to direct CP simulations, offering a pathway toward rapid multiscale modelling and uncertainty quantification.