Data-driven prediction of future melt pool from built parts during metal additive manufacturing

Smart manufacturing in metal additive manufacturing (MAM) relies on real-time process optimization through the prediction of unbuilt parts using data from built parts. Melt pool dynamics are intimately associated with the development of various microstructures during the MAM. In this paper, we demonstrate the idea by establishing a machine learning (ML) model to predict the melt pool of future parts, based on the experimental data from the National Institute of Standards and Technology (NIST) where 80 % is used for the training (built parts) and 20 % for testing (future parts). The ML model integrates both data denoising and predictive modeling. First, a convolutional neural network (CNN) is used to process a large dataset of raw melt pool images, enabling the automatic removal of noises (e.g., splash and plume) and thereof extraction of high-quality melt pool data. Following that, a novel data-driven melt pool model based on multi-layer perceptron (MLP) is trained by incorporating raw, long scanning history as input features, which best accounts for the effects of printing history (e.g., intertrack heating) on melt pool development. It takes complete advantage of MLP in handling high-dimensional regression problems in conjunction with a large dataset. Upon testing under various manufacturing conditions, the average relative error magnitude (AREM) of predicting melt pool size drops to 2.8 %, compared to 14.8 % of the prior art – the Neighboring Effect Modeling Method model (NBEM). This research thus represents a significant step towards reliable melt-pool-guided AM process optimization for smart manufacturing, enabled by advanced, flexible, and maximum use of ML techniques.