Xiaoyu Xie

Yangfan Li, Satyajit Mojumder, Ye Lu et al.

A digital twin (DT) is a virtual representation of physical process, products and/or systems that requires a high-fidelity computational model for continuous update through the integration of sensor data and user input. In the context of laser powder bed fusion (LPBF) additive manufacturing, a digital twin of the manufacturing process can offer predictions for the produced parts, diagnostics for manufacturing defects, as well as control capabilities. This paper introduces a parameterized physics-based digital twin (PPB-DT) for the statistical predictions of LPBF metal additive manufacturing process. We accomplish this by creating a high-fidelity computational model that accurately represents the melt pool phenomena and subsequently calibrating and validating it through controlled experiments. In PPB-DT, a mechanistic reduced-order method-driven stochastic calibration process is introduced, which enables the statistical predictions of the melt pool geometries and the identification of defects such as lack-of-fusion porosity and surface roughness, specifically for diagnostic applications. Leveraging data derived from this physics-based model and experiments, we have trained a machine learning-based digital twin (PPB-ML-DT) model for predicting, monitoring, and controlling melt pool geometries. These proposed digital twin models can be employed for predictions, control, optimization, and quality assurance within the LPBF process, ultimately expediting product development and certification in LPBF-based metal additive manufacturing.

Chanwook Park, Sourav Saha, Jiachen Guo et al.

Artificial intelligence (AI) has revolutionized software development, shifting from task-specific codes (Software 1.0) to neural network-based approaches (Software 2.0). However, applying this transition in engineering software presents challenges, including low surrogate model accuracy, the curse of dimensionality in inverse design, and rising complexity in physical simulations. We introduce an interpolating neural network (INN), grounded in interpolation theory and tensor decomposition, to realize Engineering Software 2.0 by advancing data training, partial differential equation solving, and parameter calibration. INN offers orders of magnitude fewer trainable/solvable parameters for comparable model accuracy than traditional multi-layer perceptron (MLP) or physics-informed neural networks (PINN). Demonstrated in metal additive manufacturing, INN rapidly constructs an accurate surrogate model of Laser Powder Bed Fusion (L-PBF) heat transfer simulation, achieving sub-10-micrometer resolution for a 10 mm path in under 15 minutes on a single GPU. This makes a transformative step forward across all domains essential to engineering software.

Xiaoyu Xie, Saviz Mowlavi, Mouhacine Benosman

Spatiotemporal modeling is critical for understanding complex systems across various scientific and engineering disciplines, but governing equations are often not fully known or computationally intractable due to inherent system complexity. Data-driven reduced-order models (ROMs) offer a promising approach for fast and accurate spatiotemporal forecasting by computing solutions in a compressed latent space. However, these models often neglect temporal correlations between consecutive snapshots when constructing the latent space, leading to suboptimal compression, jagged latent trajectories, and limited extrapolation ability over time. To address these issues, this paper introduces a continuous operator learning framework that incorporates jerk regularization into the learning of the compressed latent space. This jerk regularization promotes smoothness and sparsity of latent space dynamics, which not only yields enhanced accuracy and convergence speed but also helps identify intrinsic latent space coordinates. Consisting of an implicit neural representation (INR)-based autoencoder and a neural ODE latent dynamics model, the framework allows for inference at any desired spatial or temporal resolution. The effectiveness of this framework is demonstrated through a two-dimensional unsteady flow problem governed by the Navier-Stokes equations, highlighting its potential to expedite high-fidelity simulations in various scientific and engineering applications.