R. Sharma

R. Sharma, W. Grace Guo, M. Raissi et al.

Melt pool dynamics in metal additive manufacturing (AM) is critical to process stability, microstructure formation, and final properties of the printed materials. Physics-based simulation including computational fluid dynamics (CFD) is the dominant approach to predict melt pool dynamics. However, the physics-based simulation approaches suffer from the inherent issue of very high computational cost. This paper provides a physics-informed machine learning (PIML) method by integrating neural networks with the governing physical laws to predict the melt pool dynamics such as temperature, velocity, and pressure without using any training data on velocity. This approach avoids solving the highly non-linear Navier-Stokes equation numerically, which significantly reduces the computational cost. The difficult-to-determine model constants of the governing equations of the melt pool can also be inferred through data-driven discovery. In addition, the physics-informed neural network (PINN) architecture has been optimized for efficient model training. The data-efficient PINN model is attributed to the soft penalty by incorporating governing partial differential equations (PDEs), initial conditions, and boundary conditions in the PINN model.

M. E. Raoufat, B. Asghari, R. Sharma

Adoption of battery energy storage systems for behind-the-meters application offers valuable benefits for demand charge management as well as increasing PV-utilization. The key point is that while the benefit/cost ratio for a single application may not be favorable for economic benefits of storage systems, stacked services can provide multiple revenue streams for the same investment. Under this framework, we propose a model predictive controller to reduce demand charge cost and enhance PV-utilization level simultaneously. Different load patterns have been considered in this study and results are compared to the conventional rule-based controller. The results verified that the proposed controller provides satisfactory performance by improving the PV-utilization rate between 60% to 80% without significant changes in demand charge (DC) saving. Furthermore, our results suggest that batteries can be used for stacking multiple services to improve their benefits. Quantitative analysis for PV-utilization as a function of battery size and prediction time window has also been carried out.

Wenyi Liu, R. Sharma, W. "Grace" Guo et al.

Digital twin (DT) enables smart manufacturing by leveraging real-time data, AI models, and intelligent control systems. This paper presents a state-of-the-art analysis on the emerging field of DTs in the context of milling. The critical aspects of DT are explored through the lens of virtual models of physical milling, data flow from physical milling to virtual model, and feedback from virtual model to physical milling. Live data streaming protocols and virtual modeling methods are highlighted. A case study showcases the transformative capability of a real-time machine learning-driven live DT of tool-work contact in a milling process. Future research directions are outlined to achieve the goals of Industry 4.0 and beyond.

R. Sharma, Y. B. Guo

Understanding thermal stress evolution in metal additive manufacturing (AM) is crucial for producing high-quality components. Recent advancements in machine learning (ML) have shown great potential for modeling complex multiphysics problems in metal AM. While physics-based simulations face the challenge of high computational costs, conventional data-driven ML models require large, labeled training datasets to achieve accurate predictions. Unfortunately, generating large datasets for ML model training through time-consuming experiments or high-fidelity simulations is highly expensive in metal AM. To address these challenges, this study introduces a physics-informed neural network (PINN) framework that incorporates governing physical laws into deep neural networks (NNs) to predict temperature and thermal stress evolution during the laser metal deposition (LMD) process. The study also discusses the enhanced accuracy and efficiency of the PINN model when supplemented with small simulation data. Furthermore, it highlights the PINN transferability, enabling fast predictions with a set of new process parameters using a pre-trained PINN model as an online soft sensor, significantly reducing computation time compared to physics-based numerical models while maintaining accuracy.

R. Sharma, M. Raissi, Y. B. Guo

Efficient simulation of Laser Powder Bed Fusion (LPBF) is crucial for process prediction due to the lasting issue of high computation cost using traditional numerical methods such as finite element analysis (FEA). This study presents an efficient modeling framework termed FEA-Regulated Physics-Informed Neural Network (FEA-PINN) to accelerate the thermal field prediction in a LPBF process while maintaining the FEA accuracy. A novel dynamic material updating strategy is developed to capture the dynamic phase change of powder-liquid-solid in the PINN model. The PINN model incorporates temperature-dependent material properties and phase change behavior using the apparent heat capacity method. While the PINN model demonstrates high accuracy with a small training data and enables generalization of new process parameters via transfer learning, it faces the challenge of high computation cost in time-dependent problems due to the residual accumulation. To overcome this issue, the FEA-PINN framework integrates corrective FEA simulations during inference to enforce physical consistency and reduce error drift. A comparative analysis shows that FEA-PINN achieves equivalent accuracy to FEA while significantly reducing computational cost. The framework has been validated using the benchmark FEA data and demonstrated through single-track scanning in LPBF.

D. Patel, R. Sharma, Y. B. Guo

Metal additive manufacturing enables unprecedented design freedom and the production of customized, complex components. However, the rapid melting and solidification dynamics inherent to metal AM processes generate heterogeneous, non-equilibrium microstructures that significantly impact mechanical properties and subsequent functionality. Predicting microstructure and its evolution across spatial and temporal scales remains a central challenge for process optimization and defect mitigation. While conventional experimental techniques and physics-based simulations provide a physical foundation and valuable insights, they face critical limitations. In contrast, data-driven machine learning offers an alternative prediction approach and powerful pattern recognition but often operate as black-box, lacking generalizability and physical consistency. To overcome these limitations, physics-informed machine learning, including physics-informed neural networks, has emerged as a promising paradigm by embedding governing physical laws into neural network architectures, thereby enhancing accuracy, transparency, data efficiency, and extrapolation capabilities. This work presents a comprehensive evaluation of modeling strategies for microstructure prediction in metal AM. The strengths and limitations of experimental, computational, and data-driven methods are analyzed in depth, and highlight recent advances in hybrid PIML frameworks that integrate physical knowledge with ML. Key challenges, such as data scarcity, multi-scale coupling, and uncertainty quantification, are discussed alongside future directions. Ultimately, this assessment underscores the importance of PIML-based hybrid approaches in enabling predictive, scalable, and physically consistent microstructure modeling for site-specific, microstructure-aware process control and the reliable production of high-performance AM components.