A Physics-Informed Machine Learning Model for Porosity Analysis in Laser Powder Bed Fusion Additive Manufacturing
This work addresses porosity control for additive manufacturing, but it is incremental as it builds on existing physics-informed approaches with a focus on transferability across machines.
The paper tackled the problem of machine-dependent porosity analysis in laser powder bed fusion additive manufacturing by developing a physics-informed, data-driven model that interprets machine settings into physical effects to predict porosity levels, achieving prediction errors of 10-26%.
To control part quality, it is critical to analyze pore generation mechanisms, laying theoretical foundation for future porosity control. Current porosity analysis models use machine setting parameters, such as laser angle and part pose. However, these setting-based models are machine dependent, hence they often do not transfer to analysis of porosity for a different machine. To address the first problem, a physics-informed, data-driven model (PIM), which instead of directly using machine setting parameters to predict porosity levels of printed parts, it first interprets machine settings into physical effects, such as laser energy density and laser radiation pressure. Then, these physical, machine independent effects are used to predict porosity levels according to pass, flag, fail categories instead of focusing on quantitative pore size prediction. With six learning methods evaluation, PIM proved to achieve good performances with prediction error of 10$\sim$26%. Finally, pore-encouraging influence and pore-suppressing influence were analyzed for quality analysis.