Pouyan Sajadi

Yifan Tang, M. Rahmani Dehaghani, Pouyan Sajadi et al.

This paper aims to propose an online two-stage thermal history prediction method, which could be integrated into a metal AM process for performance control. Based on the similarity of temperature curves (curve segments of a temperature profile of one point) between any two successive layers, the first stage of the proposed method designs a layer-to-layer prediction model to estimate the temperature curves of the yet-to-print layer from measured temperatures of certain points on the previously printed layer. With measured/predicted temperature profiles of several points on the same layer, the second stage proposes a reduced order model (ROM) (intra-layer prediction model) to decompose and construct the temperature profiles of all points on the same layer, which could be used to build the temperature field of the entire layer. The training of ROM is performed with an extreme learning machine (ELM) for computational efficiency. Fifteen wire arc AM experiments and nine simulations are designed for thin walls with a fixed length and unidirectional printing of each layer. The test results indicate that the proposed prediction method could construct the thermal history of a yet-to-print layer within 0.1 seconds on a low-cost desktop computer. Meanwhile, the method has acceptable generalization capability in most cases from lower layers to higher layers in the same simulation, as well as from one simulation to a new simulation on different AM process parameters. More importantly, after fine-tuning the proposed method with limited experimental data, the relative errors of all predicted temperature profiles on a new experiment are smaller than 0.09, which demonstrates the applicability and generalization of the proposed two-stage thermal history prediction method in online applications for metal AM.

Pouyan Sajadi, Mostafa Rahmani Dehaghani, Yifan Tang et al.

Accurately predicting the temperature field in metal additive manufacturing (AM) processes is critical to preventing overheating, adjusting process parameters, and ensuring process stability. While physics-based computational models offer precision, they are often time-consuming and unsuitable for real-time predictions and online control in iterative design scenarios. Conversely, machine learning models rely heavily on high-quality datasets, which can be costly and challenging to obtain within the metal AM domain. Our work addresses this by introducing a physics-informed neural network framework specifically designed for temperature field prediction in metal AM. This framework incorporates a physics-informed input, physics-informed loss function, and a Convolutional Long Short-Term Memory (ConvLSTM) architecture. Utilizing real-time temperature data from the process, our model predicts 2D temperature fields for future timestamps across diverse geometries, deposition patterns, and process parameters. We validate the proposed framework in two scenarios: full-field temperature prediction for a thin wall and 2D temperature field prediction for cylinder and cubic parts, demonstrating errors below 3% and 1%, respectively. Our proposed framework exhibits the flexibility to be applied across diverse scenarios with varying process parameters, geometries, and deposition patterns.

Pouyan Sajadi, Mahya Qorbani, Sobhan Moosavi et al.

Traffic accidents pose a significant threat to public safety, resulting in numerous fatalities, injuries, and a substantial economic burden each year. The development of predictive models capable of real-time forecasting of post-accident impact using readily available data can play a crucial role in preventing adverse outcomes and enhancing overall safety. However, existing accident predictive models encounter two main challenges: first, reliance on either costly or non-real-time data, and second the absence of a comprehensive metric to measure post-accident impact accurately. To address these limitations, this study proposes a deep neural network model known as the cascade model. It leverages readily available real-world data from Los Angeles County to predict post-accident impacts. The model consists of two components: Long Short-Term Memory (LSTM) and Convolutional Neural Network (CNN). The LSTM model captures temporal patterns, while the CNN extracts patterns from the sparse accident dataset. Furthermore, an external traffic congestion dataset is incorporated to derive a new feature called the "accident impact" factor, which quantifies the influence of an accident on surrounding traffic flow. Extensive experiments were conducted to demonstrate the effectiveness of the proposed hybrid machine learning method in predicting the post-accident impact compared to state-of-the-art baselines. The results reveal a higher precision in predicting minimal impacts (i.e., cases with no reported accidents) and a higher recall in predicting more significant impacts (i.e., cases with reported accidents).

Yifan Tang, M. Rahmani Dehaghani, Pouyan Sajadi et al.

Considering data insufficiency in metal additive manufacturing (AM), transfer learning (TL) has been adopted to extract knowledge from source domains (e.g., completed printings) to improve the modeling performance in target domains (e.g., new printings). Current applications use all accessible source data directly in TL with no regard to the similarity between source and target data. This paper proposes a systematic method to find appropriate subsets of source data based on similarities between the source and target datasets for a given set of limited target domain data. Such similarity is characterized by the spatial and model distance metrics. A Pareto frontier-based source data selection method is developed, where the source data located on the Pareto frontier defined by two similarity distance metrics are selected iteratively. The method is integrated into an instance-based TL method (decision tree regression model) and a model-based TL method (fine-tuned artificial neural network). Both models are then tested on several regression tasks in metal AM. Comparison results demonstrate that 1) the source data selection method is general and supports integration with various TL methods and distance metrics, 2) compared with using all source data, the proposed method can find a small subset of source data from the same domain with better TL performance in metal AM regression tasks involving different processes and machines, and 3) when multiple source domains exist, the source data selection method could find the subset from one source domain to obtain comparable or better TL performance than the model constructed using data from all source domains.