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1. Morphological Dynamics-Based Anomaly Detection Towards In Situ Layer-Wise Certification for Directed Energy Deposition Processes

   https://doi.org/10.1115/1.4054805  

   Bappy, Mahathir Mohammad ; Liu, Chenang ; Bian, Linkan ; Tian, Wenmeng ( November 2022 , Journal of Manufacturing Science and Engineering)

   Abstract The process uncertainty induced quality issue remains the major challenge that hinders the wider adoption of additive manufacturing (AM) technology. The defects occurred significantly compromise structural integrity and mechanical properties of fabricated parts. Therefore, there is an urgent need in fast, yet reliable AM component certification. Most finite element analysis related methods characterize defects based on the thermomechanical relationships, which are computationally inefficient and cannot capture process uncertainty. In addition, there is a growing trend in data-driven approaches on characterizing the empirical relationships between thermal history and anomaly occurrences, which focus on modeling an individual image basis to identify local defects. Despite their effectiveness in local anomaly detection, these methods are quite cumbersome when applied to layer-wise anomaly detection. This paper proposes a novel in situ layer-wise anomaly detection method by analyzing the layer-by-layer morphological dynamics of melt pools and heat affected zones (HAZs). Specifically, the thermal images are first preprocessed based on the g-code to assure unified orientation. Subsequently, the melt pool and HAZ are segmented, and the global and morphological transition metrics are developed to characterize the morphological dynamics. New layer-wise features are extracted, and supervised machine learning methods are applied for layer-wise anomaly detection. The proposed method is validated using the directed energy deposition (DED) process, which demonstrates superior performance comparing with the benchmark methods. The average computational time is significantly shorter than the average build time, enabling in situ layer-wise certification and real-time process control. 

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2. Multiresolution Quality Inspection of Layerwise Builds for Metal 3D Printer and Scanner

   https://doi.org/10.1115/1.4057013  

   Yang, Hui ; Reijonen, Joni ; Revuelta, Alejandro ( October 2023 , Journal of Manufacturing Science and Engineering)

   Automated optical inspection (AOI) is increasingly advocated for in situ quality monitoring of additive manufacturing (AM) processes. The availability of layerwise imaging data improves the information visibility during fabrication processes and is thus conducive to performing online certification. However, few, if any, have investigated the high-speed contact image sensors (CIS) (i.e., originally developed for document scanners and multifunction printers) for AM quality monitoring. In addition, layerwise images show complex patterns and often contain hidden information that cannot be revealed in a single scale. A new and alternative approach will be to analyze these intrinsic patterns with multiscale lenses. Therefore, the objective of this article is to design and develop an AOI system with contact image sensors for multiresolution quality inspection of layerwise builds in additive manufacturing. First, we retrofit the AOI system with contact image sensors in industrially relevant 95 mm/s scanning speed to a laser-powder-bed-fusion (LPBF) machines. Then, we design the experiments to fabricate nine parts under a variety of factor levels (e.g., gas flow blockage, re-coater damage, laser power changes). In each layer, the AOI system collects imaging data of both recoating powder beds before the laser fusion and surface finishes after the laser fusion. Second, layerwise images are pre-preprocessed for alignment, registration, and identification of regions of interests (ROIs) of these nine parts. Then, we leverage the wavelet transformation to analyze ROI images in multiple scales and further extract salient features that are sensitive to process variations, instead of extraneous noises. Third, we perform the paired comparison analysis to investigate how different levels of factors influence the distribution of wavelet features. Finally, these features are shown to be effective in predicting the extent of defects in the computed tomography (CT) data of layerwise AM builds. The proposed framework of multiresolution quality inspection is evaluated and validated using real-world AM imaging data. Experimental results demonstrated the effectiveness of the proposed AOI system with contact image sensors for online quality inspection of layerwise builds in AM processes.

    

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3. A Deep Learning-Based Real-time Seizure Detection System

   https://doi.org/10.1109/SPMB50085.2020.9353623  

   Shawki, N. ; Elseify, T. ; Cap, T. ; Shah, V. ; Obeid, I. ; Picone, J. ( December 2020 , Proceedings of the IEEE Signal Processing in Medicine and Biology Symposium (SPMB))

   Obeid, Iyad Selesnick (Ed.)

   Electroencephalography (EEG) is a popular clinical monitoring tool used for diagnosing brain-related disorders such as epilepsy [1]. As monitoring EEGs in a critical-care setting is an expensive and tedious task, there is a great interest in developing real-time EEG monitoring tools to improve patient care quality and efficiency [2]. However, clinicians require automatic seizure detection tools that provide decisions with at least 75% sensitivity and less than 1 false alarm (FA) per 24 hours [3]. Some commercial tools recently claim to reach such performance levels, including the Olympic Brainz Monitor [4] and Persyst 14 [5]. In this abstract, we describe our efforts to transform a high-performance offline seizure detection system [3] into a low latency real-time or online seizure detection system. An overview of the system is shown in Figure 1. The main difference between an online versus offline system is that an online system should always be causal and has minimum latency which is often defined by domain experts. The offline system, shown in Figure 2, uses two phases of deep learning models with postprocessing [3]. The channel-based long short term memory (LSTM) model (Phase 1 or P1) processes linear frequency cepstral coefficients (LFCC) [6] features from each EEG channel separately. We use the hypotheses generated by the P1 model and create additional features that carry information about the detected events and their confidence. The P2 model uses these additional features and the LFCC features to learn the temporal and spatial aspects of the EEG signals using a hybrid convolutional neural network (CNN) and LSTM model. Finally, Phase 3 aggregates the results from both P1 and P2 before applying a final postprocessing step. The online system implements Phase 1 by taking advantage of the Linux piping mechanism, multithreading techniques, and multi-core processors. To convert Phase 1 into an online system, we divide the system into five major modules: signal preprocessor, feature extractor, event decoder, postprocessor, and visualizer. The system reads 0.1-second frames from each EEG channel and sends them to the feature extractor and the visualizer. The feature extractor generates LFCC features in real time from the streaming EEG signal. Next, the system computes seizure and background probabilities using a channel-based LSTM model and applies a postprocessor to aggregate the detected events across channels. The system then displays the EEG signal and the decisions simultaneously using a visualization module. The online system uses C++, Python, TensorFlow, and PyQtGraph in its implementation. The online system accepts streamed EEG data sampled at 250 Hz as input. The system begins processing the EEG signal by applying a TCP montage [8]. Depending on the type of the montage, the EEG signal can have either 22 or 20 channels. To enable the online operation, we send 0.1-second (25 samples) length frames from each channel of the streamed EEG signal to the feature extractor and the visualizer. Feature extraction is performed sequentially on each channel. The signal preprocessor writes the sample frames into two streams to facilitate these modules. In the first stream, the feature extractor receives the signals using stdin. In parallel, as a second stream, the visualizer shares a user-defined file with the signal preprocessor. This user-defined file holds raw signal information as a buffer for the visualizer. The signal preprocessor writes into the file while the visualizer reads from it. Reading and writing into the same file poses a challenge. The visualizer can start reading while the signal preprocessor is writing into it. To resolve this issue, we utilize a file locking mechanism in the signal preprocessor and visualizer. Each of the processes temporarily locks the file, performs its operation, releases the lock, and tries to obtain the lock after a waiting period. The file locking mechanism ensures that only one process can access the file by prohibiting other processes from reading or writing while one process is modifying the file [9]. The feature extractor uses circular buffers to save 0.3 seconds or 75 samples from each channel for extracting 0.2-second or 50-sample long center-aligned windows. The module generates 8 absolute LFCC features where the zeroth cepstral coefficient is replaced by a temporal domain energy term. For extracting the rest of the features, three pipelines are used. The differential energy feature is calculated in a 0.9-second absolute feature window with a frame size of 0.1 seconds. The difference between the maximum and minimum temporal energy terms is calculated in this range. Then, the first derivative or the delta features are calculated using another 0.9-second window. Finally, the second derivative or delta-delta features are calculated using a 0.3-second window [6]. The differential energy for the delta-delta features is not included. In total, we extract 26 features from the raw sample windows which add 1.1 seconds of delay to the system. We used the Temple University Hospital Seizure Database (TUSZ) v1.2.1 for developing the online system [10]. The statistics for this dataset are shown in Table 1. A channel-based LSTM model was trained using the features derived from the train set using the online feature extractor module. A window-based normalization technique was applied to those features. In the offline model, we scale features by normalizing using the maximum absolute value of a channel [11] before applying a sliding window approach. Since the online system has access to a limited amount of data, we normalize based on the observed window. The model uses the feature vectors with a frame size of 1 second and a window size of 7 seconds. We evaluated the model using the offline P1 postprocessor to determine the efficacy of the delayed features and the window-based normalization technique. As shown by the results of experiments 1 and 4 in Table 2, these changes give us a comparable performance to the offline model. The online event decoder module utilizes this trained model for computing probabilities for the seizure and background classes. These posteriors are then postprocessed to remove spurious detections. The online postprocessor receives and saves 8 seconds of class posteriors in a buffer for further processing. It applies multiple heuristic filters (e.g., probability threshold) to make an overall decision by combining events across the channels. These filters evaluate the average confidence, the duration of a seizure, and the channels where the seizures were observed. The postprocessor delivers the label and confidence to the visualizer. The visualizer starts to display the signal as soon as it gets access to the signal file, as shown in Figure 1 using the “Signal File” and “Visualizer” blocks. Once the visualizer receives the label and confidence for the latest epoch from the postprocessor, it overlays the decision and color codes that epoch. The visualizer uses red for seizure with the label SEIZ and green for the background class with the label BCKG. Once the streaming finishes, the system saves three files: a signal file in which the sample frames are saved in the order they were streamed, a time segmented event (TSE) file with the overall decisions and confidences, and a hypotheses (HYP) file that saves the label and confidence for each epoch. The user can plot the signal and decisions using the signal and HYP files with only the visualizer by enabling appropriate options. For comparing the performance of different stages of development, we used the test set of TUSZ v1.2.1 database. It contains 1015 EEG records of varying duration. The any-overlap performance [12] of the overall system shown in Figure 2 is 40.29% sensitivity with 5.77 FAs per 24 hours. For comparison, the previous state-of-the-art model developed on this database performed at 30.71% sensitivity with 6.77 FAs per 24 hours [3]. The individual performances of the deep learning phases are as follows: Phase 1’s (P1) performance is 39.46% sensitivity and 11.62 FAs per 24 hours, and Phase 2 detects seizures with 41.16% sensitivity and 11.69 FAs per 24 hours. We trained an LSTM model with the delayed features and the window-based normalization technique for developing the online system. Using the offline decoder and postprocessor, the model performed at 36.23% sensitivity with 9.52 FAs per 24 hours. The trained model was then evaluated with the online modules. The current performance of the overall online system is 45.80% sensitivity with 28.14 FAs per 24 hours. Table 2 summarizes the performances of these systems. The performance of the online system deviates from the offline P1 model because the online postprocessor fails to combine the events as the seizure probability fluctuates during an event. The modules in the online system add a total of 11.1 seconds of delay for processing each second of the data, as shown in Figure 3. In practice, we also count the time for loading the model and starting the visualizer block. When we consider these facts, the system consumes 15 seconds to display the first hypothesis. The system detects seizure onsets with an average latency of 15 seconds. Implementing an automatic seizure detection model in real time is not trivial. We used a variety of techniques such as the file locking mechanism, multithreading, circular buffers, real-time event decoding, and signal-decision plotting to realize the system. A video demonstrating the system is available at: https://www.isip.piconepress.com/projects/nsf_pfi_tt/resources/videos/realtime_eeg_analysis/v2.5.1/video_2.5.1.mp4. The final conference submission will include a more detailed analysis of the online performance of each module. ACKNOWLEDGMENTS Research reported in this publication was most recently supported by the National Science Foundation Partnership for Innovation award number IIP-1827565 and the Pennsylvania Commonwealth Universal Research Enhancement Program (PA CURE). Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the official views of any of these organizations. REFERENCES [1] A. Craik, Y. He, and J. L. Contreras-Vidal, “Deep learning for electroencephalogram (EEG) classification tasks: a review,” J. Neural Eng., vol. 16, no. 3, p. 031001, 2019. https://doi.org/10.1088/1741-2552/ab0ab5. [2] A. C. Bridi, T. Q. Louro, and R. C. L. Da Silva, “Clinical Alarms in intensive care: implications of alarm fatigue for the safety of patients,” Rev. Lat. Am. Enfermagem, vol. 22, no. 6, p. 1034, 2014. https://doi.org/10.1590/0104-1169.3488.2513. [3] M. Golmohammadi, V. Shah, I. Obeid, and J. Picone, “Deep Learning Approaches for Automatic Seizure Detection from Scalp Electroencephalograms,” in Signal Processing in Medicine and Biology: Emerging Trends in Research and Applications, 1st ed., I. Obeid, I. Selesnick, and J. Picone, Eds. New York, New York, USA: Springer, 2020, pp. 233–274. https://doi.org/10.1007/978-3-030-36844-9_8. [4] “CFM Olympic Brainz Monitor.” [Online]. Available: https://newborncare.natus.com/products-services/newborn-care-products/newborn-brain-injury/cfm-olympic-brainz-monitor. [Accessed: 17-Jul-2020]. [5] M. L. Scheuer, S. B. Wilson, A. Antony, G. Ghearing, A. Urban, and A. I. Bagic, “Seizure Detection: Interreader Agreement and Detection Algorithm Assessments Using a Large Dataset,” J. Clin. Neurophysiol., 2020. https://doi.org/10.1097/WNP.0000000000000709. [6] A. Harati, M. Golmohammadi, S. Lopez, I. Obeid, and J. Picone, “Improved EEG Event Classification Using Differential Energy,” in Proceedings of the IEEE Signal Processing in Medicine and Biology Symposium, 2015, pp. 1–4. https://doi.org/10.1109/SPMB.2015.7405421. [7] V. Shah, C. Campbell, I. Obeid, and J. Picone, “Improved Spatio-Temporal Modeling in Automated Seizure Detection using Channel-Dependent Posteriors,” Neurocomputing, 2021. [8] W. Tatum, A. Husain, S. Benbadis, and P. Kaplan, Handbook of EEG Interpretation. New York City, New York, USA: Demos Medical Publishing, 2007. [9] D. P. Bovet and C. Marco, Understanding the Linux Kernel, 3rd ed. O’Reilly Media, Inc., 2005. https://www.oreilly.com/library/view/understanding-the-linux/0596005652/. [10] V. Shah et al., “The Temple University Hospital Seizure Detection Corpus,” Front. Neuroinform., vol. 12, pp. 1–6, 2018. https://doi.org/10.3389/fninf.2018.00083. [11] F. Pedregosa et al., “Scikit-learn: Machine Learning in Python,” J. Mach. Learn. Res., vol. 12, pp. 2825–2830, 2011. https://dl.acm.org/doi/10.5555/1953048.2078195. [12] J. Gotman, D. Flanagan, J. Zhang, and B. Rosenblatt, “Automatic seizure detection in the newborn: Methods and initial evaluation,” Electroencephalogr. Clin. Neurophysiol., vol. 103, no. 3, pp. 356–362, 1997. https://doi.org/10.1016/S0013-4694(97)00003-9. 

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4. Thermal Modeling in Metal Additive Manufacturing Using Graph Theory

   https://doi.org/10.1115/1.4043648  

   Yavari, M. Reza ; Cole, Kevin D. ; Rao, Prahalada ( July 2019 , Journal of Manufacturing Science and Engineering)

   The goal of this work is to predict the effect of part geometry and process parameters on the instantaneous spatiotemporal distribution of temperature, also called the thermal field or temperature history, in metal parts as they are being built layer-by-layer using additive manufacturing (AM) processes. In pursuit of this goal, the objective of this work is to develop and verify a graph theory-based approach for predicting the temperature distribution in metal AM parts. This objective is consequential to overcome the current poor process consistency and part quality in AM. One of the main reasons for poor part quality in metal AM processes is ascribed to the nature of temperature distribution in the part. For instance, steep thermal gradients created in the part during printing leads to defects, such as warping and thermal stress-induced cracking. Existing nonproprietary approaches to predict the temperature distribution in AM parts predominantly use mesh-based finite element analyses that are computationally tortuous—the simulation of a few layers typically requires several hours, if not days. Hence, to alleviate these challenges in metal AM processes, there is a need for efficient computational models to predict the temperature distribution, and thereby guide part design and selection of process parameters instead of expensive empirical testing. Compared with finite element analyses techniques, the proposed mesh-free graph theory-based approach facilitates prediction of the temperature distribution within a few minutes on a desktop computer. To explore these assertions, we conducted the following two studies: (1) comparing the heat diffusion trends predicted using the graph theory approach with finite element analysis, and analytical heat transfer calculations based on Green’s functions for an elementary cuboid geometry which is subjected to an impulse heat input in a certain part of its volume and (2) simulating the laser powder bed fusion metal AM of three-part geometries with (a) Goldak’s moving heat source finite element method, (b) the proposed graph theory approach, and (c) further comparing the thermal trends predicted from the last two approaches with a commercial solution. From the first study, we report that the thermal trends approximated by the graph theory approach are found to be accurate within 5% of the Green’s functions-based analytical solution (in terms of the symmetric mean absolute percentage error). Results from the second study show that the thermal trends predicted for the AM parts using graph theory approach agree with finite element analyses, and the computational time for predicting the temperature distribution was significantly reduced with graph theory. For instance, for one of the AM part geometries studied, the temperature trends were predicted in less than 18 min within 10% error using the graph theory approach compared with over 180 min with finite element analyses. Although this paper is restricted to theoretical development and verification of the graph theory approach, our forthcoming research will focus on experimental validation through in-process thermal measurements. 

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5. Toward the digital twin of additive manufacturing: Integrating thermal simulations, sensing, and analytics to detect process faults

   https://doi.org/10.1080/24725854.2019.1701753  

   Gaikwad, Aniruddha ; Yavari, Reza ; Montazeri, Mohammad ; Cole, Kevin ; Bian, Linkan ; Rao, Prahalada ( January 2020 , IISE Transactions)

   The goal of this work to mitigate flaws in metal parts produced from laser powder bed fusion (LPBF) additive manufacturing (AM) process. As a step towards this goal, the objective of this work is to predict the build quality of a part as it is being printed via deep learning of in-situ layer-wise images obtained from an optical camera instrumented in the LPBF machine. To realize this objective, we designed a set of thin-wall features (fins) from Titanium alloy (Ti-6Al-4V) material with varying length-to-thickness ratio. These thin-wall test parts were printed under three different build orientations and in-situ images of their top surface were acquired during the process. The parts were examined offline using X-ray computed tomography (XCT), and their build quality was quantified in terms of statistical features, such as the thickness and consistency of its edges. Subsequently, a deep learning convolutional neural network (CNN) was trained to predict the XCT-derived statistical quality features using the layer-wise optical images of the thin-wall part as inputs. The statistical correlation between CNN-based predictions and XCT-observed quality measurements exceeds 85%. This work has two outcomes consequential to the sustainability of additive manufacturing: (1) It provides practitioners with a guideline for building thin-wall features with minimal defects, and (2) the high correlation between the offline XCT measurements and in-situ sensor-based quality metrics substantiates the potential for applying deep learning approaches for the real-time prediction of build flaws in LPBF. 

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