Thermophysical Phenomena in Metal Additive Manufacturing by Selective Laser Melting: Fundamentals, Modeling, Simulation and Experimentation

Among the many additive manufacturing (AM) processes for metallic materials, selective laser melting (SLM) is arguably the most versatile in terms of its potential to realize complex geometries along with tailored microstructure. However, the complexity of the SLM process, and the need for predictive relation of powder and process parameters to the part properties, demands further development of computational and experimental methods. This review addresses the fundamental physical phenomena of SLM, with a special emphasis on the associated thermal behavior. Simulation and experimental methods are discussed according to three primary categories. First, macroscopic approaches aim to answer questions at the component level and consider for example the determination of residual stresses or dimensional distortion effects prevalent in SLM. Second, mesoscopic approaches focus on the detection of defects such as excessive surface roughness, residual porosity or inclusions that occur at the mesoscopic length scale of individual powder particles. Third, microscopic approaches investigate the metallurgical microstructure evolution resulting from the high temperature gradients and extreme heating and cooling rates induced by the SLM process. Consideration of physical phenomena on all of these three length scales is mandatory to establish the understanding needed to realize high part quality in many applications, and to fully exploit the potential of SLM and related metal AM processes

Learning Shape Priors for Single-View 3D Completion and Reconstruction

The problem of single-view 3D shape completion or reconstruction is challenging, because among the many possible shapes that explain an observation, most are implausible and do not correspond to natural objects. Recent research in the field has tackled this problem by exploiting the expressiveness of deep convolutional networks. In fact, there is another level of ambiguity that is often overlooked: among plausible shapes, there are still multiple shapes that fit the 2D image equally well; i.e., the ground truth shape is non-deterministic given a single-view input. Existing fully supervised approaches fail to address this issue, and often produce blurry mean shapes with smooth surfaces but no fine details. In this paper, we propose ShapeHD, pushing the limit of single-view shape completion and reconstruction by integrating deep generative models with adversarially learned shape priors. The learned priors serve as a regularizer, penalizing the model only if its output is unrealistic, not if it deviates from the ground truth. Our design thus overcomes both levels of ambiguity aforementioned. Experiments demonstrate that ShapeHD outperforms state of the art by a large margin in both shape completion and shape reconstruction on multiple real datasets.Comment: ECCV 2018. The first two authors contributed equally to this work. Project page: http://shapehd.csail.mit.edu

Iterative Amortized Inference

Inference models are a key component in scaling variational inference to deep latent variable models, most notably as encoder networks in variational auto-encoders (VAEs). By replacing conventional optimization-based inference with a learned model, inference is amortized over data examples and therefore more computationally efficient. However, standard inference models are restricted to direct mappings from data to approximate posterior estimates. The failure of these models to reach fully optimized approximate posterior estimates results in an amortization gap. We aim toward closing this gap by proposing iterative inference models, which learn to perform inference optimization through repeatedly encoding gradients. Our approach generalizes standard inference models in VAEs and provides insight into several empirical findings, including top-down inference techniques. We demonstrate the inference optimization capabilities of iterative inference models and show that they outperform standard inference models on several benchmark data sets of images and text.Comment: International Conference on Machine Learning (ICML) 201

3D Shape Segmentation with Projective Convolutional Networks

This paper introduces a deep architecture for segmenting 3D objects into their labeled semantic parts. Our architecture combines image-based Fully Convolutional Networks (FCNs) and surface-based Conditional Random Fields (CRFs) to yield coherent segmentations of 3D shapes. The image-based FCNs are used for efficient view-based reasoning about 3D object parts. Through a special projection layer, FCN outputs are effectively aggregated across multiple views and scales, then are projected onto the 3D object surfaces. Finally, a surface-based CRF combines the projected outputs with geometric consistency cues to yield coherent segmentations. The whole architecture (multi-view FCNs and CRF) is trained end-to-end. Our approach significantly outperforms the existing state-of-the-art methods in the currently largest segmentation benchmark (ShapeNet). Finally, we demonstrate promising segmentation results on noisy 3D shapes acquired from consumer-grade depth cameras.Comment: This is an updated version of our CVPR 2017 paper. We incorporated new experiments that demonstrate ShapePFCN performance under the case of consistent *upright* orientation and an additional input channel in our rendered images for encoding height from the ground plane (upright axis coordinate values). Performance is improved in this settin

BSP-fields: An Exact Representation of Polygonal Objects by Differentiable Scalar Fields Based on Binary Space Partitioning

The problem considered in this work is to find a dimension independent algorithm for the generation of signed scalar fields exactly representing polygonal objects and satisfying the following requirements: the defining real function takes zero value exactly at the polygonal object boundary; no extra zero-value isosurfaces should be generated; C1 continuity of the function in the entire domain. The proposed algorithms are based on the binary space partitioning (BSP) of the object by the planes passing through the polygonal faces and are independent of the object genus, the number of disjoint components, and holes in the initial polygonal mesh. Several extensions to the basic algorithm are proposed to satisfy the selected optimization criteria. The generated BSP-fields allow for applying techniques of the function-based modeling to already existing legacy objects from CAD and computer animation areas, which is illustrated by several examples

Effects of intraparticle heat and mass transfer during devolatilization of a single coal particle

The objective of the present work is to elucidate the influence of intraparticle mass and heat transfer phenomena on the overall rate and product yields during devolatilization of a single coal particle in an inert atmosphere. To this end a mathematical model has been formulated which covers transient devolatilization kinetics and intraparticle mass and heat transport. Secondary deposition reactions of tarry volatiles also are included. These specific features of the model allow a quantitative assessment to be made of the impact of major process conditions such as the coal particle size, the ambient pressure and the heating rate on the tar, gas and total volatile yield during devolatilization. Model predictions are compared to a limited number of experimental results, both from the present work and from various literature sources

CFD modeling of a fixed-bed biofilm reactor coupling hydrodynamics and biokinetics

Peer ReviewedPostprint (author's final draft