Bead geometry prediction in wire arc directed energy deposition using physics-informed machine learning and low-fidelity data

IF 11.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING
Asif Rashid, Farzad Vatandoust, Akshar Kota, Shreyes N. Melkote
{"title":"Bead geometry prediction in wire arc directed energy deposition using physics-informed machine learning and low-fidelity data","authors":"Asif Rashid,&nbsp;Farzad Vatandoust,&nbsp;Akshar Kota,&nbsp;Shreyes N. Melkote","doi":"10.1016/j.addma.2025.104881","DOIUrl":null,"url":null,"abstract":"<div><div>Wire Arc Directed Energy Deposition (Wire Arc DED) is a promising metal additive manufacturing technique, yet accurate bead geometry prediction remains a challenge due to the complex thermal and geometric interactions in the process. In this study, we present a coupled Physics-Informed Neural Network (PINN) framework to predict the bead geometry by integrating the governing process physics and experimental data, thereby addressing the limitations of both computationally expensive numerical models and purely data-driven approaches. The model employs a sequential two-step workflow, where a thermal model first predicts temperature evolution, which subsequently informs a geometry model for predicting the bead geometry. Results indicate that a high-fidelity PINN model with high spatiotemporal resolution captures the intricately coupled thermal and geometric variations inherent to bead deposition with good predictive accuracy albeit at a higher computational cost, while a low-fidelity PINN model with lower spatiotemporal resolution offers a computationally efficient alternative with marginally higher errors. The incorporation of measured bead geometry data significantly enhances prediction accuracy, with a minimal amount of low-fidelity data sufficing to refine predictions effectively. Moreover, the model generalizes well across different bead locations along the deposition length, demonstrating reliable performance. The high-fidelity PINN model, using a temporal step size of 0.2 s, achieves an average height prediction error of 8.38 % and width error of 1.09 % after approximately 12.7 hours of training on four H100 GPUs. In contrast, the low-fidelity model, with a coarser temporal step size of 0.5 s, reaches nearly the same accuracy (8.33 % height error, 1.56 % width error) with just 2.7 h of training on a single H100 GPU. This corresponds to a 79 % reduction in training time and substantially lower hardware requirements, highlighting the scalability and efficiency of the proposed hybrid modeling approach.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104881"},"PeriodicalIF":11.1000,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Additive manufacturing","FirstCategoryId":"5","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S2214860425002453","RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"ENGINEERING, MANUFACTURING","Score":null,"Total":0}
引用次数: 0

Abstract

Wire Arc Directed Energy Deposition (Wire Arc DED) is a promising metal additive manufacturing technique, yet accurate bead geometry prediction remains a challenge due to the complex thermal and geometric interactions in the process. In this study, we present a coupled Physics-Informed Neural Network (PINN) framework to predict the bead geometry by integrating the governing process physics and experimental data, thereby addressing the limitations of both computationally expensive numerical models and purely data-driven approaches. The model employs a sequential two-step workflow, where a thermal model first predicts temperature evolution, which subsequently informs a geometry model for predicting the bead geometry. Results indicate that a high-fidelity PINN model with high spatiotemporal resolution captures the intricately coupled thermal and geometric variations inherent to bead deposition with good predictive accuracy albeit at a higher computational cost, while a low-fidelity PINN model with lower spatiotemporal resolution offers a computationally efficient alternative with marginally higher errors. The incorporation of measured bead geometry data significantly enhances prediction accuracy, with a minimal amount of low-fidelity data sufficing to refine predictions effectively. Moreover, the model generalizes well across different bead locations along the deposition length, demonstrating reliable performance. The high-fidelity PINN model, using a temporal step size of 0.2 s, achieves an average height prediction error of 8.38 % and width error of 1.09 % after approximately 12.7 hours of training on four H100 GPUs. In contrast, the low-fidelity model, with a coarser temporal step size of 0.5 s, reaches nearly the same accuracy (8.33 % height error, 1.56 % width error) with just 2.7 h of training on a single H100 GPU. This corresponds to a 79 % reduction in training time and substantially lower hardware requirements, highlighting the scalability and efficiency of the proposed hybrid modeling approach.
利用物理信息机器学习和低保真度数据预测导线电弧定向能沉积中的磁珠几何形状
电弧定向能沉积(Wire Arc DED)是一种很有前途的金属增材制造技术,但由于过程中复杂的热和几何相互作用,准确预测焊头几何形状仍然是一个挑战。在这项研究中,我们提出了一个耦合的物理信息神经网络(PINN)框架,通过整合控制过程物理和实验数据来预测头的几何形状,从而解决了计算昂贵的数值模型和纯数据驱动方法的局限性。该模型采用了连续的两步工作流程,其中热模型首先预测温度变化,然后通知几何模型来预测管柱的几何形状。结果表明,具有高时空分辨率的高保真PINN模型能够以较高的计算成本捕获珠状沉积固有的复杂耦合的热和几何变化,具有良好的预测精度,而具有较低时空分辨率的低保真PINN模型提供了计算效率高的替代方案,但误差略高。结合测量的磁珠几何数据显著提高了预测精度,少量的低保真度数据就足以有效地改进预测。此外,该模型沿沉积长度可以很好地推广到不同的头位置,显示出可靠的性能。采用0.2 s的时间步长,在4台H100 gpu上训练约12.7 小时后,高保真PINN模型的平均高度预测误差为8.38 %,宽度预测误差为1.09 %。相比之下,低保真度模型,具有较粗的时间步长0.5 s,达到几乎相同的精度(8.33 %高度误差,1.56 %宽度误差),在单个H100 GPU上仅训练2.7 h。这相当于减少了79% %的训练时间,大大降低了硬件需求,突出了所提出的混合建模方法的可伸缩性和效率。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
求助全文
约1分钟内获得全文 求助全文
来源期刊
Additive manufacturing
Additive manufacturing Materials Science-General Materials Science
CiteScore
19.80
自引率
12.70%
发文量
648
审稿时长
35 days
期刊介绍: Additive Manufacturing stands as a peer-reviewed journal dedicated to delivering high-quality research papers and reviews in the field of additive manufacturing, serving both academia and industry leaders. The journal's objective is to recognize the innovative essence of additive manufacturing and its diverse applications, providing a comprehensive overview of current developments and future prospects. The transformative potential of additive manufacturing technologies in product design and manufacturing is poised to disrupt traditional approaches. In response to this paradigm shift, a distinctive and comprehensive publication outlet was essential. Additive Manufacturing fulfills this need, offering a platform for engineers, materials scientists, and practitioners across academia and various industries to document and share innovations in these evolving technologies.
×
引用
GB/T 7714-2015
复制
MLA
复制
APA
复制
导出至
BibTeX EndNote RefMan NoteFirst NoteExpress
×
提示
您的信息不完整,为了账户安全,请先补充。
现在去补充
×
提示
您因"违规操作"
具体请查看互助需知
我知道了
×
提示
确定
请完成安全验证×
copy
已复制链接
快去分享给好友吧!
我知道了
右上角分享
点击右上角分享
0
联系我们:info@booksci.cn Book学术提供免费学术资源搜索服务,方便国内外学者检索中英文文献。致力于提供最便捷和优质的服务体验。 Copyright © 2023 布克学术 All rights reserved.
京ICP备2023020795号-1
ghs 京公网安备 11010802042870号
Book学术文献互助
Book学术文献互助群
群 号:604180095
Book学术官方微信