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Title: Uncovering acoustic signatures of pore formation in laser powder bed fusion
Abstract

We present a machine learning workflow to discover signatures in acoustic measurements that can be utilized to create a low-dimensional model to accurately predict the location of keyhole pores formed during additive manufacturing processes. Acoustic measurements were sampled at 100 kHz during single-layer laser powder bed fusion (LPBF) experiments, and spatio-temporal registration of pore locations was obtained from post-build radiography. Power spectral density (PSD) estimates of the acoustic data were then decomposed using non-negative matrix factorization with custom$$\varvec{k}$$k-means clustering (NMF$$\varvec{k}$$k) to learn the underlying spectral patterns associated with pore formation. NMF$$\varvec{k}$$kreturned a library of basis signals and matching coefficients toblindlyconstruct a feature space based on the PSD estimates in anoptimizedfashion. Moreover, the NMF$$\varvec{k}$$kdecomposition led to the development of computationally inexpensive machine learning models which are capable of quickly and accurately identifying pore formation with classification accuracy of supervised and unsupervised label learning greater than 95% and 90%, respectively. The intrinsic data compression of NMFk, the relatively light computational cost of the machine learning workflow, and the high classification accuracy makes the proposed workflow an attractive candidate for edge computing toward in-situ keyhole pore prediction in LPBF.

 
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NSF-PAR ID:
10482867
Author(s) / Creator(s):
; ; ; ; ; ; ; ; ; ;
Publisher / Repository:
Springer Science + Business Media
Date Published:
Journal Name:
The International Journal of Advanced Manufacturing Technology
Volume:
130
Issue:
5-6
ISSN:
0268-3768
Format(s):
Medium: X Size: p. 3103-3114
Size(s):
["p. 3103-3114"]
Sponsoring Org:
National Science Foundation
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