Process control for WAAM using computer vision

This study is mainly about the vision system and control algorithm programming for wire arc additive manufacturing (WAAM). Arc additive manufacturing technology is formed by the principle of heat source cladding produced by welders using molten inert gas shielded welding (MIG), tungsten inert gas shielded welding (TIG) and layered plasma welding power supply (PA). It has high deposition efficiency, short manufacturing cycle, low cost, and easy maintenance. Although WAAM has very good uses in various fields, the inability to control the adding process in real time has led to defects in the weld and reduced quality. Therefore, it is necessary to develop the real-time feedback through computer vision and algorithms for WAAM to ensure that the thickness and the width of each layer during the addition process are the same

Neural Network Modelling of Track Profile in Cold Spray Additive Manufacturing.

Cold spray additive manufacturing is an emerging technology that offers the ability to deposit oxygen-sensitive materials and to manufacture large components in the solid state. For further development of the technology, the geometric control of cold sprayed components is fundamental but not yet fully matured. This study presents a neural network predictive modelling of a single-track profile in cold spray additive manufacturing to address the problem. In contrast to previous studies focusing only on key geometric feature predictions, the neural network model was employed to demonstrate its capability of predicting complete track profiles at both normal and off-normal spray angles, resulting in a mean absolute error of 8.3%. We also compared the track profile modelling results against the previously proposed Gaussian model and showed that the neural network model provided comparable predictive accuracy, even outperforming in the predictions at cold spray profile edges. The results indicate that a neural network modelling approach is well suited to cold spray profile prediction and may be used to improve geometric control during additive manufacturing with an appropriate process planning algorithm.This research was funded by CSIRO’s Active Integrated Matter Future Science Platform (AIM FSP)under the testbed number: TB10_WB04

Online Two-stage Thermal History Prediction Method for Metal Additive Manufacturing of Thin Walls

This paper aims to propose an online two-stage thermal history prediction method, which could be integrated into a metal AM process for performance control. Based on the similarity of temperature curves (curve segments of a temperature profile of one point) between any two successive layers, the first stage of the proposed method designs a layer-to-layer prediction model to estimate the temperature curves of the yet-to-print layer from measured temperatures of certain points on the previously printed layer. With measured/predicted temperature profiles of several points on the same layer, the second stage proposes a reduced order model (ROM) (intra-layer prediction model) to decompose and construct the temperature profiles of all points on the same layer, which could be used to build the temperature field of the entire layer. The training of ROM is performed with an extreme learning machine (ELM) for computational efficiency. Fifteen wire arc AM experiments and nine simulations are designed for thin walls with a fixed length and unidirectional printing of each layer. The test results indicate that the proposed prediction method could construct the thermal history of a yet-to-print layer within 0.1 seconds on a low-cost desktop computer. Meanwhile, the method has acceptable generalization capability in most cases from lower layers to higher layers in the same simulation, as well as from one simulation to a new simulation on different AM process parameters. More importantly, after fine-tuning the proposed method with limited experimental data, the relative errors of all predicted temperature profiles on a new experiment are smaller than 0.09, which demonstrates the applicability and generalization of the proposed two-stage thermal history prediction method in online applications for metal AM.Comment: 30 pages, 21 figures, 2 table

Layer-to-Layer Feedback Control for Direct Energy Deposition Additive Manufacturing

Additive manufacturing (AM) has garnered much attention in recent years, some calling it the fourth industrial revolution. It was first used to create rapid prototypes, although recent efforts have been made to advance the technology towards production of functional parts. This requires advancement in the materials used in AM, as well as the ability to produce quality parts repeatably. More specifically, direct energy deposition (DED) of metal powders is a process capable of producing and repairing parts with complex geometries; however, it is not widely used in industry due to challenges with quality control. In this process, metal powder is dispensed from a nozzle and a laser beam melts the incident powder particles and a portion of the underlying surface. The melt pool is translated along the desired toolpath and parts are constructed in a layer-by-layer fashion. Several process inputs determine the deposition quality, including powder feed rate, laser power and nozzle speed. These inputs, as well as the environmental conditions, are subject to random fluctuations that can cause geometric defects during deposition. Such defects often propagate through to subsequent layers and are amplified, rendering the final part unusable. The objective of this work is to improve the geometric accuracy of parts produced by metal powder DED by designing and implementing process feedback control. The strategy involves measuring the part height after each layer and adjusting the nozzle speed trajectory for the next layer according to a designed control law. The major contributions of this work are 1. the construction of an open-architecture metal powder DED system that is capable of implementing layer-to-layer control and 2. the development of controllers to improve part morphology accuracy in metal powder DED --Abstract, p. i

Real-Time 2D Temperature Field Prediction in Metal Additive Manufacturing Using Physics-Informed Neural Networks

Accurately predicting the temperature field in metal additive manufacturing (AM) processes is critical to preventing overheating, adjusting process parameters, and ensuring process stability. While physics-based computational models offer precision, they are often time-consuming and unsuitable for real-time predictions and online control in iterative design scenarios. Conversely, machine learning models rely heavily on high-quality datasets, which can be costly and challenging to obtain within the metal AM domain. Our work addresses this by introducing a physics-informed neural network framework specifically designed for temperature field prediction in metal AM. This framework incorporates a physics-informed input, physics-informed loss function, and a Convolutional Long Short-Term Memory (ConvLSTM) architecture. Utilizing real-time temperature data from the process, our model predicts 2D temperature fields for future timestamps across diverse geometries, deposition patterns, and process parameters. We validate the proposed framework in two scenarios: full-field temperature prediction for a thin wall and 2D temperature field prediction for cylinder and cubic parts, demonstrating errors below 3% and 1%, respectively. Our proposed framework exhibits the flexibility to be applied across diverse scenarios with varying process parameters, geometries, and deposition patterns.Comment: 42 pages, 13 Figure

Relaxing Fundamental Assumptions in Iterative Learning Control

Iterative learning control (ILC) is perhaps best decribed as an open loop feedforward control technique where the feedforward signal is learned through repetition of a single task. As the name suggests, given a dynamic system operating on a finite time horizon with the same desired trajectory, ILC aims to iteratively construct the inverse image (or its approximation) of the desired trajectory to improve transient tracking. In the literature, ILC is often interpreted as feedback control in the iteration domain due to the fact that learning controllers use information from past trials to drive the tracking error towards zero. However, despite the significant body of literature and powerful features, ILC is yet to reach widespread adoption by the control community, due to several assumptions that restrict its generality when compared to feedback control. In this dissertation, we relax some of these assumptions, mainly the fundamental invariance assumption, and move from the idea of learning through repetition to two dimensional systems, specifically repetitive processes, that appear in the modeling of engineering applications such as additive manufacturing, and sketch out future research directions for increased practicality: We develop an L1 adaptive feedback control based ILC architecture for increased robustness, fast convergence, and high performance under time varying uncertainties and disturbances. Simulation studies of the behavior of this combined L1-ILC scheme under iteration varying uncertainties lead us to the robust stability analysis of iteration varying systems, where we show that these systems are guaranteed to be stable when the ILC update laws are designed to be robust, which can be done using existing methods from the literature. As a next step to the signal space approach adopted in the analysis of iteration varying systems, we shift the focus of our work to repetitive processes, and show that the exponential stability of a nonlinear repetitive system is equivalent to that of its linearization, and consequently uniform stability of the corresponding state space matrix.PhDElectrical Engineering: SystemsUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttp://deepblue.lib.umich.edu/bitstream/2027.42/133232/1/altin_1.pd

Non-Contact Height Estimation for Material Extrusion Additive Systems via Monocular Imagery

Additive manufacturing is a dynamic technology with a compelling potential to advance the manufacturing industry. Despite its capacity to produce intricate designs in an efficient manner, industry still has not widely adopted additive manufacturing since its commercialization as a result of its many challenges related to quality control. The Air Force Research Laboratory (AFRL), Materials and Manufacturing Directorate, Functional Materials Division, Soft Matter Materials Branch (RXAS) requires a practical and reliable method for maintaining quality control for the production of printed flexible electronics. Height estimation is a crucial component for maintaining quality control in Material Extrusion Additive Manufacturing (MEAM), as the fundamental process for constructing any structure relies on the consecutive layering of precise extrusions. This work presents a computer vision solution to the problem of height estimation using monocular imagery as applicable to MEAM

Harnessing the Power of Digital Twins for Enhanced Material Behavior Prediction and Manufacturing Process Optimization in Materials Engineering

The advent of Industry 4.0 and the digital revolution have brought forth innovative technologies such as digital twins, which have the potential to redefine the landscape of materials engineering. Digital twins, virtual representations of physical entities, can model and predict material behavior, enabling enhanced design, testing, and manufacturing of materials. However, the comprehensive utilization of digital twins for predictive analysis and process optimization in materials engineering remains largely uncharted. This research intends to delve into this intriguing intersection, investigating the capabilities of digital twins in predicting material behavior and optimizing manufacturing processes, thereby contributing to the evolution of advanced materials manufacturing. Our study will commence with a detailed exploration of the concept of digital twins and their specific applications in materials engineering, emphasizing their ability to simulate intricate material behaviors and processes in a virtual environment. Subsequently, we will focus on exploiting digital twins for predicting diverse material behaviors such as mechanical properties, failure modes, and phase transformations, demonstrating how digital twins can utilize a combination of historical data, real-time monitoring, and sophisticated algorithms to predict outcomes accurately. Furthermore, we will delve into the role of digital twins in optimizing materials manufacturing processes, including casting, machining, and additive manufacturing, illustrating how digital twins can model these processes, identify potential issues, and suggest optimal parameters. We will present detailed case studies to provide practical insights into the implementation of digital twins in materials engineering, including the advantages and challenges. The final segment of our research will address the current challenges in implementing digital twins, such as data quality, model validation, and computational demands, proposing potential solutions and outlining future directions. This research aims to underline the transformative potential of digital twins in materials engineering, thereby paving the way for more efficient, sustainable, and intelligent material design and manufacturing processes