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Wire-feed laser additive manufacturing (WLAM) is gaining wide interest due to its high level of automation, high deposition rates, and good quality of printed parts. In-process monitoring and feedback controls that would reduce the uncertainty in the quality of the material are in the early stages of development. Machine learning promises the ability to accelerate the adoption of new processes and property design in additive manufacturing by making process-structure-property connections between process setting inputs and material quality outcomes. The molten pool dimensional information and temperature are the indicators for achieving the high quality of the build, which can be directly controlled by processing parameters. For the purpose of in situ quality control, the process parameters should be controlled in real-time based on sensed information from the process, in particular the molten pool. Thus, the molten pool-process relations are of preliminary importance. This paper analyzes experimentally collected in situ sensing data from the molten pool under a set of controlled process parameters in a WLAM system. The variations in the steady-state and transient state of the molten pool are presented with respect to the change of independent process parameters. A multi-modality convolutional neural network (CNN) architecture is proposed for predicting the control parameter directly from the measurable molten pool sensor data for achieving desired geometric and microstructural properties. Dropout and regularization are applied to the CNN architecture to avoid the problem of overfitting. The results highlighted that the multi-modal CNN, which receives temperature profile as an external feature to the features extracted from the image data, has improved prediction performance compared to the image-based uni-modality CNN approach.
Wire-feed laser additive manufacturing is an emerging fabrication technique capable of highly automated large-scale volume production that can reduce both material waste and overall cost while improving product lead times. Quality assurance is necess
The advancement of machine learning promises the ability to accelerate the adoption of new processes and property designs for metal additive manufacturing. The molten pool geometry and molten pool temperature are the significant indicators for the fi
The future of space exploration missions will rely on technologies increasing their endurance and self-sufficiency, including for manufacturing objects on-demand. We propose a process for handling and additively manufacturing powders that functions i
A thick electrode with high areal capacity has been developed as a strategy for high-energy-density lithium-ion batteries, but thick electrodes have difficulties in manufacturing and limitations in ion transport. Here, we reported a new manufacturing
Additive manufacturing (AM) technology is being increasingly adopted in a wide variety of application areas due to its ability to rapidly produce, prototype, and customize designs. AM techniques afford significant opportunities in regard to nuclear m