In-situ defect detection in laser-directed energy deposition with machine learning and multi-sensor fusion

IF 1.5 4区 工程技术 Q3 ENGINEERING, MECHANICAL
Lequn Chen, Seung Ki Moon
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引用次数: 0

Abstract

Early defect identification in laser-directed energy deposition (L-DED) additive manufacturing (AM) is pivotal for preventing build failures. Traditional single-modal monitoring approaches lack the capability to fully comprehend process dynamics, leading to a gap in multisensor monitoring strategies. This research proposes a novel in-situ monitoring method using a multi-sensor fusion-based digital twin (MFDT) for localized quality prediction, coupled with machine learning (ML) models for data fusion. It investigates acoustic signals from laser-material interactions as defect indicators, crafting a ML-based pipeline for rapid defect detection via feature extraction, fusion, and classification. This approach not only explores acoustic features across multiple domains, as well as coaxial melt pool images for ML model training, but it also introduces a novel MFDT framework that combines data from coaxial melt pool vision cameras and microphones, synchronized with robotic movements, to predict localized quality attributes. The key novelty in this research is the exploration of intra-modality and cross-modality multisensor feature correlations, revealing key vision and acoustic signatures associated with varying process dynamics. A comprehensive understanding of how multi-sensor signature varies with process dynamics improves the effectiveness of the proposed multi-sensor fusion model. The proposed model outperforms conventional methods with a 96.4 % accuracy, thereby setting a solid foundation for future self-adaptive quality improvement strategies in AM.

利用机器学习和多传感器融合技术在激光定向能量沉积过程中进行原位缺陷检测
激光直接能量沉积(L-DED)增材制造(AM)中的早期缺陷识别对于防止制造失败至关重要。传统的单模式监测方法缺乏全面了解过程动态的能力,导致多传感器监测策略出现空白。本研究提出了一种新型原位监测方法,使用基于多传感器融合的数字孪生(MFDT)进行局部质量预测,并结合机器学习(ML)模型进行数据融合。它将激光与材料相互作用产生的声学信号作为缺陷指标进行研究,通过特征提取、融合和分类,精心设计了一个基于 ML 的管道,用于快速缺陷检测。该方法不仅探索了多个领域的声学特征,以及用于 ML 模型训练的同轴熔池图像,还引入了一个新颖的 MFDT 框架,该框架结合了来自同轴熔池视觉相机和麦克风的数据,并与机器人运动同步,以预测局部质量属性。这项研究的主要创新点在于探索了多传感器的模内和跨模特征相关性,揭示了与不同过程动态相关的关键视觉和声学特征。对多传感器特征如何随流程动态变化的全面了解提高了所提出的多传感器融合模型的有效性。所提出的模型以 96.4% 的准确率超越了传统方法,从而为未来 AM 的自适应质量改进策略奠定了坚实的基础。
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来源期刊
Journal of Mechanical Science and Technology
Journal of Mechanical Science and Technology 工程技术-工程:机械
CiteScore
2.90
自引率
6.20%
发文量
517
审稿时长
7.7 months
期刊介绍: The aim of the Journal of Mechanical Science and Technology is to provide an international forum for the publication and dissemination of original work that contributes to the understanding of the main and related disciplines of mechanical engineering, either empirical or theoretical. The Journal covers the whole spectrum of mechanical engineering, which includes, but is not limited to, Materials and Design Engineering, Production Engineering and Fusion Technology, Dynamics, Vibration and Control, Thermal Engineering and Fluids Engineering. Manuscripts may fall into several categories including full articles, solicited reviews or commentary, and unsolicited reviews or commentary related to the core of mechanical engineering.
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