Abstract
Due to its unique benefits over standard conventional “subtractive” manufacturing, additive manufacturing is attracting growing interest in academic and industrial sectors. Here, special emphasis is given to wire arc additive manufacturing (WAAM), a directed energy deposition process that employs arc welding tools and wire to build metallic components by deposition of weld material. The WAAM process has several advantages, e.g., low cost, rapid deposition rate, and suitability for large complex metallic components. However, many WAAM challenges such as large welding deformation, undesirable porosity, and components with high residual stress remain to be overcome. Multidisciplinary cross-fusion research involving manufacturing, material science, automation control, and artificial intelligence/machine learning (ML) are deployed to overcome the above-mentioned problems. ML enables improved product quality control, process optimization, and modeling of complex multiphysics systems in the WAAM process. This research utilizes a data-driven literature review process, a defined and deliberate approach to localizing, evaluating, and analyzing published studies in the literature. The most relevant studies in the literature are analyzed using keyword co-occurrence and cluster analysis. Numerous aspects of WAAM, including design for WAAM, material analytics/characterization, defect detection/monitoring, as well as process modeling and optimization, have been examined to identify state-of-the-art research in ML for WAAM. Finally, the challenges and opportunities for using ML in the WAAM process are identified and summarized.
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Abbreviations
- 1D:
-
One-dimensional
- 2D:
-
Two-dimensional
- 3D:
-
Three-dimensional
- ABR:
-
Adaboostregressor
- ADRC:
-
Active disturbance rejection control
- AE:
-
Arc extinguishing
- AI:
-
Artificial intelligence
- AM:
-
Additive manufacturing
- ANFIS:
-
Adaptive neuro-fuzzy inference system
- ANN:
-
Artificial neural networks
- AS:
-
Arc striking
- BGO:
-
Bio-geography-based optimizer
- BH:
-
Bead height
- BW:
-
Bead width
- CAD:
-
Computer aided design
- CCT:
-
Continuous cooling transformation
- CMES:
-
Covariance matrix adaptation evolution strategy
- CMT:
-
Cold metal transfer
- CNN:
-
Convolutional neural network
- ConvLSTM:
-
Convolutional lstm
- CS:
-
Cuckoo search
- DED:
-
Directed energy deposition
- DfAM:
-
Design for am
- DfWAAM:
-
Design for WAAM
- DL:
-
Deep learning
- DOE:
-
Design of experiments
- DT:
-
Decision tree
- ELM:
-
Extreme learning machines
- EPNet:
-
Efficient patch-based deep network
- FA:
-
Firefly algorithm
- FEA:
-
Finite element analysis
- FNN:
-
Feedforward neural network
- FPGA:
-
Field-programmable gate array
- GA:
-
Genetic algorithm
- GANs:
-
Generative adversarial networks
- GBR:
-
Gradient boosting regressor
- GF:
-
Gas flow rate
- GMAW:
-
Gas metal arc welding
- GPR:
-
Gaussian process regressor
- GRU:
-
Gated recurrent unit
- GTAW:
-
Gas tungsten arc welding
- GWO:
-
Grey wolf optimization
- ICME:
-
Integrated computational materials engineering
- IoT:
-
Internet of things
- IT:
-
Interpass temperature
- KNN:
-
K-nearest neighbor
- LCA:
-
Life-cycle analysis
- LPBF:
-
Laser powder bed fusion
- LPP:
-
Locality-preserving projection
- LR:
-
Linear regression
- LSTM:
-
Long short-term memory
- MFAILC:
-
Model-free adaptive iterative learning control
- ML:
-
Machine learning
- MLP:
-
Multi-layer perceptron
- NoSQL:
-
Not only structured query language
- PAW:
-
Plasma arc welding
- PRT:
-
Pseudo-random ternary
- PSO:
-
Particle swarm optimization
- PSPP:
-
Process-structure-properties-performance
- RBFNN:
-
Radial basis function networks
- ResNet:
-
Residual neural network
- REST:
-
Representational state transfer
- RF:
-
Random forest
- RL:
-
Reinforcement learning
- RNN:
-
Recurrent neural network
- RoI:
-
Region-of-interest
- SEM:
-
Scanning electron microscopy
- STL:
-
Stereolithography
- SVR/SVM:
-
Support vector regressor/machine
- TLBO:
-
Teaching–learning-based optimization
- TS:
-
Travel speed
- VAE:
-
Variational autoencoders
- VGG-16:
-
Convolutional neural network with 16 hidden layers
- WAAM:
-
Wire arc additive manufacturing
- WF:
-
Wire feed rate
- WFS:
-
Wire feed speed
- XGBR:
-
Extreme gradient boosting regressor
- YOLO_v3:
-
You only look once_version 3
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Arvind Agarwal acknowledges the financial support of DEVCOM—Army Research Laboratory (ARL) Grant W911NF2020256.
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Hamrani, A., Agarwal, A., Allouhi, A. et al. Applying machine learning to wire arc additive manufacturing: a systematic data-driven literature review. J Intell Manuf (2023). https://doi.org/10.1007/s10845-023-02171-8
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DOI: https://doi.org/10.1007/s10845-023-02171-8