Machine learning-assisted in-situ adaptive strategies for the control of defects and anomalies in metal additive manufacturing

Additive manufacturing, Journal Year: 2024, Volume and Issue: 81, P. 104013 - 104013

Published: Feb. 1, 2024

In metal additive manufacturing (AM), the material microstructure and part geometry are formed incrementally. Consequently, resulting could be defect- anomaly-free if sufficient care is taken to deposit each layer under optimal process conditions. Conventional closed-loop control (CLC) engineering solutions which sought achieve this were deterministic rule-based, thus in limited success stochastic environment experienced highly dynamic AM process. On other hand, emerging machine learning (ML) based strategies better suited providing robustness, scope, flexibility, scalability required for an uncertain environment. Offline ML models that help optimise parameters before a build begins online efficiently processed in-situ sensory data detect diagnose flaws real-time (or near-real-time) have been developed. However, enable take evasive or corrective actions relation via on fly decision-making only emerging. These must possess prognostic capabilities provide context-sensitive recommendations diagnostics. article, we pinpoint shortcomings traditional CLC strategies, framework defect anomaly through ML-assisted AM. We discuss terms of their causes, detectability, controllability, examine management three scenarios: avoidance, mitigation, repair. Then, summarise research into developed offline optimisation diagnosis initiating detailed conversation implementation control. found researchers favoured reinforcement approaches inverse making rapid, situation-aware decisions. also observed that, to-date, defects addressed those may quantified relatively easily autonomously, mitigation (rather than avoidance repair) was aim strategies. Additionally, highlight various technologies seamlessly combine advance field autonomous so it becomes reality industrial settings. Finally, raise awareness seldom discussed, yet pertinent, topics relevant adaptive Our work closes significant gap current literature by broaching wide-ranging discussions matters

Language: Английский

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Advancements in Laser Wire-Feed Metal Additive Manufacturing: A Brief Review

Materials, Journal Year: 2023, Volume and Issue: 16(5), P. 2030 - 2030

Published: March 1, 2023

Laser Wire-Feed Metal Additive Manufacturing (LWAM) is a process that utilizes laser to heat and melt metallic alloy wire, which then precisely positioned on substrate, or previous layer, build three-dimensional metal part. LWAM technology offers several advantages, such as high speed, cost effectiveness, precision control, the ability create complex geometries with near-net shape features improved metallurgical properties. However, still in its early stages of development, integration into industry ongoing. To provide comprehensive understanding technology, this review article emphasizes importance key aspects LWAM, including parametric modeling, monitoring systems, control algorithms, path-planning approaches. The study aims identify potential gaps existing literature highlight future research opportunities field goal advancing industrial application.

Language: Английский

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A Review on Wire-Laser Directed Energy Deposition: Parameter Control, Process Stability, and Future Research Paths

Journal of Manufacturing and Materials Processing, Journal Year: 2024, Volume and Issue: 8(2), P. 84 - 84

Published: April 20, 2024

Wire-laser directed energy deposition has emerged as a transformative technology in metal additive manufacturing, offering high material efficiency and promoting cleaner process environment compared to powder processes. This technique gained attention across diverse industries due its ability expedite production facilitate the repair or replication of valuable components. work reviews state-of-the-art wire-laser gain clear understanding key variables identify challenges affecting stability. Furthermore, this paper explores modeling monitoring methods utilized literature enhance final quality fabricated parts, thereby minimizing need for repeated experiments, reducing waste. By reviewing existing literature, contributes advancing current technology. It highlights gaps while underscoring research needs deposition.

Language: Английский

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From Geometric Precision to Performance:Improved Online Monitoring System for Thin-Walled Parts by Fine Wire Laser Directed Energy Deposition

Deleted Journal, Journal Year: 2025, Volume and Issue: unknown, P. 200201 - 200201

Published: Feb. 1, 2025

Language: Английский

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Effects of the thermal history on the microstructural and the mechanical properties of stainless steel 316L parts produced by wire-based laser metal deposition

Materials Science and Engineering A, Journal Year: 2023, Volume and Issue: 889, P. 145862 - 145862

Published: Oct. 30, 2023

Laser metal deposition with coaxial wire feeding is a novel technology for additively manufacturing near-net-shape parts, as well repairing and modifying existing components. The microstructure and, thus, the mechanical properties of deposited material significantly depend on thermal history part, which influenced by process parameters amount dissipated heat energy. In order to investigate these correlations, stainless steel 316L samples were produced under different conditions thoroughly characterized. Solid cuboids built substrate plate at room temperature preheated plate. Subsequently, influence melt pool temperatures was evaluated, microstructures, microhardness, tensile analyzed. It found that mean primary dendrite arm spacing (PDAS) increased build height, while cooling rates showed an inverse relationship height. determined PDAS values correlated microhardness profile specimens using Hall-Petch type relationship. An accumulation in parts thereby associated coarser diminished properties. presented results pave way tailoring manufactured components specific requirements.

Language: Английский

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Segmentation-based closed-loop layer height control for enhancing stability and dimensional accuracy in wire-based laser metal deposition

Robotics and Computer-Integrated Manufacturing, Journal Year: 2023, Volume and Issue: 86, P. 102683 - 102683

Published: Nov. 16, 2023

Laser metal deposition (LMD) with wire is a versatile additive manufacturing process used for the production of near-net-shape components as well modification and repair applications. Major advantages using feedstock material opposed to powder include elimination hazardous dust in environment lower costs. However, highly sensitive disturbances requires significant effort parameter tuning. Thus, order achieve stable defined geometric properties over many layers, dedicated approaches monitoring control are essential. In particular, maintaining constant distance between workpiece surface head an important prerequisite stability. Therefore, this work, layer height system wire-based LMD was implemented. The objective ensure corresponding specified increment even case disturbances. Using laser line scanner, profile part obtained after each deposited layer. weld beads were then divided into small segments obtain fully discrete profile, feed rate next set by individual controller within segment. implemented tested its effectiveness under different disturbances, whereby differences could be compensated few layers. developed segmentation approach found effective method dimensional accuracy components. This work thus constitutes major contribution advancement automated metallic

Language: Английский

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Multi laser beams directed energy deposition of a high-strength and high-toughness TC11 titanium alloy with coaxial wire feeding

Next Materials, Journal Year: 2025, Volume and Issue: 8, P. 100576 - 100576

Published: March 4, 2025

Language: Английский

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Two-dimensional temperature field prediction with in-situ data in metal additive manufacturing using physics-informed neural networks

Engineering Applications of Artificial Intelligence, Journal Year: 2025, Volume and Issue: 150, P. 110636 - 110636

Published: March 23, 2025

Language: Английский

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High-quality and high-resolution thin-wall fabrication of A5183 aluminum alloy using wire-laser metal 3D printer

The International Journal of Advanced Manufacturing Technology, Journal Year: 2025, Volume and Issue: unknown

Published: April 11, 2025

Language: Английский

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Assessment of structural defects and mechanical characteristics of IN718/St6 functionally graded material produced by direct laser deposition

Journal of Materials Research and Technology, Journal Year: 2024, Volume and Issue: 31, P. 1557 - 1570

Published: June 26, 2024

Functionally graded materials (FGM) do not show special processing in the composite structure due to combination of mechanical, thermal, magnetic and stress gradient properties. The aim this study is produce IN718/St6 FGM samples by direct laser deposition method. product model should enable development mechanical products. Best all, can be done without significant reduction texture case residual that are a consequence rapid changes thermal properties non-FGM samples. To fabricate part, system equipped with 1 kW continuous fiber used, SEM/EDS analysis microhardness testing measure porosity, chemical composition, quantify used. In study, cladding composition selected from 100% IN718 St6 25% change composition. prevent formation defects, both single-parameter modes individual layering examined, considering diverse nature combination. result shows using an structure, reduces Lack fusion defects structure. EDS confirmed content gradually increased first fifth layer. substrate hardness increases 200 Vickers 550 hardness, showing almost linear trend. Moreover, layering, coaxial reduced 55% relative orientation vertical line 18° compared directly (non-FGM).

Language: Английский

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