Advanced Predictive Quality Assessment for Ultrasonic Additive Manufacturing with Deep Learning Model
It addresses quality assurance for UAM manufacturing environments, but is incremental as it applies existing CNN methods to a new domain-specific dataset.
This study tackled the problem of inter-layer defects in Ultrasonic Additive Manufacturing (UAM) by developing a deep learning-based CNN method to monitor in-process quality using thermal images, achieving accuracies above 97% across various scenarios, such as 98.29% for combined baseline and thermocouple images.
Ultrasonic Additive Manufacturing (UAM) employs ultrasonic welding to bond similar or dissimilar metal foils to a substrate, resulting in solid, consolidated metal components. However, certain processing conditions can lead to inter-layer defects, affecting the final product's quality. This study develops a method to monitor in-process quality using deep learning-based convolutional neural networks (CNNs). The CNN models were evaluated on their ability to classify samples with and without embedded thermocouples across five power levels (300W, 600W, 900W, 1200W, 1500W) using thermal images with supervised labeling. Four distinct CNN classification models were created for different scenarios including without (baseline) and with thermocouples, only without thermocouples across power levels, only with thermocouples across power levels, and combined without and with thermocouples across power levels. The models achieved 98.29% accuracy on combined baseline and thermocouple images, 97.10% for baseline images across power levels, 97.43% for thermocouple images, and 97.27% for both types across power levels. The high accuracy, above 97%, demonstrates the system's effectiveness in identifying and classifying conditions within the UAM process, providing a reliable tool for quality assurance and process control in manufacturing environments.