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Applying machine learning to wire arc additive manufacturing: a systematic data-driven literature review

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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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Acknowledgements

Arvind Agarwal acknowledges the financial support of DEVCOM—Army Research Laboratory (ARL) Grant W911NF2020256.

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Correspondence to Abderrachid Hamrani.

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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

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