Applications of Machine Learning in Process Monitoring and Controls of L-PBF Additive Manufacturing: A Review
Bibliographic record
Abstract
One of the main issues hindering the adoption of parts produced using laser powder bed fusion (L-PBF) in safety-critical applications is the inconsistencies in quality levels. Furthermore, the complicated nature of the L-PBF process makes optimizing process parameters to reduce these defects experimentally challenging and computationally expensive. To address this issue, sensor-based monitoring of the L-PBF process has gained increasing attention in recent years. Moreover, integrating machine learning (ML) techniques to analyze the collected sensor data has significantly improved the defect detection process aiming to apply online control. This article provides a comprehensive review of the latest applications of ML for in situ monitoring and control of the L-PBF process. First, the main L-PBF process signatures are described, and the suitable sensor and specifications that can monitor each signature are reviewed. Next, the most common ML learning approaches and algorithms employed in L-PBFs are summarized. Then, an extensive comparison of the different ML algorithms used for defect detection in the L-PBF process is presented. The article then describes the ultimate goal of applying ML algorithms for in situ sensors, which is closing the loop and taking online corrective actions. Finally, some current challenges and ideas for future work are also described to provide a perspective on the future directions for research dealing with using ML applications for defect detection and control for the L-PBF processes.
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How this classification was reachedexpand
Full frame machine prediction
Teacher imitationNot calibrated prevalence, not ground truth. Human validation pending. The Gemma side is a direct model label for every work in the frame, read from the title-only record. The Codex side is a classifier learned from the 10,348 direct Codex labels and calibrated to design-weighted sample rates; fields without enough sample support carry no Codex call. Candidate is the union of the two sides; consensus is their intersection. These outputs are machine_predicted_unvalidated and are not human labels.
Distilled classifier scores by category (both heads)
| Category | Codex | Gemma |
|---|---|---|
| Metaresearch | 0.001 | 0.001 |
| Meta-epidemiology (narrow) | 0.001 | 0.001 |
| Meta-epidemiology (broad) | 0.001 | 0.001 |
| Bibliometrics | 0.003 | 0.003 |
| Science and technology studies | 0.000 | 0.000 |
| Scholarly communication | 0.001 | 0.002 |
| Open science | 0.001 | 0.001 |
| Research integrity | 0.002 | 0.001 |
| Insufficient payload (model declined to judge) | 0.003 | 0.002 |
Machine scores (provisional)
The two teacher heads of the student model, read on this work. A score orders the frame for review; it never asserts a category, and the validation status ships verbatim with every row.
Baseline scores from an immature model (maturity gate not passed, 7 training rounds). Scores rank; they never assert a category.
score_only:v0-immature-baseline · verbatim from the scoring run: score_only means the number may rank works, and no category label ships from itClassification
machine, unvalidatedMachine predicted; a candidate call from one source (direct Gemma or distilled Codex), not a consensus.
How this classification was reached, model by model and score by score, is at the end of the page under "How this classification was reached".