M. Raissi

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.

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.