scholarly journals Laser Powder Bed Fusion Parameter Selection via Machine-Learning-Augmented Process Modeling

JOM ◽  
2020 ◽  
Vol 72 (12) ◽  
pp. 4393-4403
Author(s):  
Sandeep Srinivasan ◽  
Brennan Swick ◽  
Michael A. Groeber
Keyword(s):  
Machine Learning ◽  
Process Modeling ◽  
Parameter Selection ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed

A Physics-Informed Two-Level Machine Learning Model for Predicting Melt-Pool Size in Laser Powder Bed Fusion

2021 ◽  
Author(s):  
Yong Ren ◽  
Qian Wang ◽  
Panagiotis (Pan) Michaleris
Keyword(s):  
Machine Learning ◽  
Initial Temperature ◽  
Pool Size ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Melt Pool ◽  
Input Feature ◽  
Melt Pool Size ◽  
Melt Pool Characteristics

Abstract Laser powder bed fusion (L-PBF) additive manufacturing (AM) is one type of metal-based AM process that is capable of producing high-value complex components with a fine geometric resolution. As melt-pool characteristics such as melt-pool size and dimensions are highly correlated with porosity and defects in the fabricated parts, it is crucial to predict how process parameters would affect the melt-pool size and dimensions during the build process to ensure the build quality. This paper presents a two-level machine learning (ML) model to predict the melt-pool size during the scanning of a multi-track build. To account for the effect of thermal history on melt-pool size, a so-called (pre-scan) initial temperature is predicted at the lower-level of the modeling architecture, and then used as a physics-informed input feature at the upper-level for the prediction of melt-pool size. Simulated data sets generated from the Autodesk's Netfabb Simulation are used for model training and validation. Through numerical simulations, the proposed two-level ML model has demonstrated a high prediction performance and its prediction accuracy improves significantly compared to a naive one-level ML without using the initial temperature as an input feature.

scholarly journals Automatic Quality Assessments of Laser Powder Bed Fusion Builds from Photodiode Sensor Measurements

2020 ◽  
Author(s):  
Sarini Jayasinghe ◽  
Paolo Paoletti ◽  
Chris Sutcliffe ◽  
John Dardis ◽  
Nick Jones ◽  
...  
Keyword(s):  
Machine Learning ◽  
Gaussian Process ◽  
Learning Algorithms ◽  
Gaussian Process Regression ◽  
Machine Learning Algorithms ◽  
Sensor Data ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Part Density

This study evaluates whether a combination of photodiode sensor measurements, taken during laser powder bed fusion (L-PBF) builds, can be used to predict the resulting build quality via a purely data-based approach. We analyse the relationship between build density and features that are extracted from sensor data collected from three different photodiodes. The study uses a Singular Value Decomposition to extract lower-dimensional features from photodiode measurements, which are then fed into machine learning algorithms. Several unsupervised learning methods are then employed to classify low density (< 99% part density) and high density (≥ 99% part density) specimens. Subsequently, a supervised learning method (Gaussian Process regression) is used to directly predict build density. Using the unsupervised clustering approaches, applied to features extracted from both photodiode sensor data as well as observations relating to the energy transferred to the material, build density was predicted with up to 93.54% accuracy. With regard to the supervised regression approach, a Gaussian Process algorithm was capable of predicting the build density with a RMS error of 3.65%. The study shows, therefore, that there is potential for machine learning algorithms to predict indicators of L-PBF build quality from photodiode build-measurements. Moreover, the work herein describes approaches that are predominantly probabilistic, thus facilitating uncertainty quantification in machine-learnt predictions of L-PBF build quality.

Focus Variation Measurement and Prediction of Surface Texture Parameters Using Machine Learning in Laser Powder Bed Fusion

2019 ◽  
Vol 142 (1) ◽  
Author(s):  
Tuğrul Özel ◽  
Ayça Altay ◽  
Bilgin Kaftanoğlu ◽  
Richard Leach ◽  
Nicola Senin ◽  
...  
Keyword(s):  
Machine Learning ◽  
Energy Density ◽  
Surface Topography ◽  
Process Parameters ◽  
Surface Texture ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Texture Parameters ◽  
Focus Variation

Abstract The powder bed fusion-based additive manufacturing process uses a laser to melt and fuse powder metal material together and creates parts with intricate surface topography that are often influenced by laser path, layer-to-layer scanning strategies, and energy density. Surface topography investigations of as-built, nickel alloy (625) surfaces were performed by obtaining areal height maps using focus variation microscopy for samples produced at various energy density settings and two different scan strategies. Surface areal height maps and measured surface texture parameters revealed the highly irregular nature of surface topography created by laser powder bed fusion (LPBF). Effects of process parameters and energy density on the areal surface texture have been identified. Machine learning methods were applied to measured data to establish input and output relationships between process parameters and measured surface texture parameters with predictive capabilities. The advantages of utilizing such predictive models for process planning purposes are highlighted.

scholarly journals Monitoring via Machine‐Learning: Machine‐Learning‐Based Monitoring of Laser Powder Bed Fusion (Adv. Mater. Technol. 12/2018)

2018 ◽  
Vol 3 (12) ◽  
pp. 1870051 ◽  
Author(s):  
Bodi Yuan ◽  
Gabriel M. Guss ◽  
Aaron C. Wilson ◽  
Stefan P. Hau‐Riege ◽  
Phillip J. DePond ◽  
...  
Keyword(s):  
Machine Learning ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Learning Machine
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