Fig. 1 Experimental proof of CSRO existence. a TEM image of the selected defect-free zone for SAED. b1–b2 [112] diffraction patterns showed extra 1/2{1$\stackrel{\text{-}}{3}$1} superlattice spots. b2 is the enhanced version of b1 with brightness and contrast refined; c Fourier-filtered HRTEM image and its SAED; d picture showing the presence of CSRO by superimposing the IFFT of extra spots and the filtered HRTEM matrix. The yellow-dashed circle highlights the clustering of CSRO, while the inlet exhibits the CSRO lattice structure; and e as-built cellular microstructure

Fig. 2 MD simulation results of LPBF process. a1-4 Snapshots of melting stages and a5-8 cooling stages. b The structure fraction-time curves and the S-L interface position curves. The interface position was determined when the “solidified” region contained 99.9% of the FCC atoms. c The concentrations of Cr, Co, and Ni in solid (S) and liquid (L) regions during the cooling stages. No concentration difference was seen between liquid and solid phases, which indicated complete solute trapping

Fig. 3 Comparison of three models. a Schematic of how the AM model was created based on the solidified LPBF model. b Comparison of atomic configurations. c Schematic of intrinsic SFE calculation. d Schematic of how the AMdeform model was created. Two ends containing as-built dislocations and vacancies were removed. The atomic configurations of the MC/MDdeform and RSSdeform models are available in Fig. S3 in Supplementary Information

Fig. 4 Results of a, b deformation simulations, c WCP calculations and d other valuable results of the AM, MC/MD, and RSS models. Sessile dislocations include 1/6 <110> stair-rod and 1/3 <001> Hirth dislocations. Movable dislocations include 1/2 <110> perfect, 1/6 <112> Shockley, and 1/3 <111> Frank dislocations. All dislocation types were identified using the dislocation analysis modifier (DXA) in Ovito. The flow stress was defined as the average stress on the strain section from 20 to 25%. εdislocation and εHCP were determined when the first dislocation showed up and when the HCP phase fraction first exceeded 0.2%, respectively