A Supervised Machine Learning Model for Regression to Predict Melt Pool Formation and Morphology in Laser Powder Bed Fusion
In the additive manufacturing laser powder bed fusion (L-PBF) process, the optimization of the print process parameters and the development of conduction zones in the laser power (P) and scanning speed (V) parameter spaces are critical to meeting production quality, productivity, and volume goals. I...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-12-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/14/1/328 |
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| author | Niccolò Baldi Alessandro Giorgetti Alessandro Polidoro Marco Palladino Iacopo Giovannetti Gabriele Arcidiacono Paolo Citti |
| author_facet | Niccolò Baldi Alessandro Giorgetti Alessandro Polidoro Marco Palladino Iacopo Giovannetti Gabriele Arcidiacono Paolo Citti |
| author_sort | Niccolò Baldi |
| collection | DOAJ |
| description | In the additive manufacturing laser powder bed fusion (L-PBF) process, the optimization of the print process parameters and the development of conduction zones in the laser power (P) and scanning speed (V) parameter spaces are critical to meeting production quality, productivity, and volume goals. In this paper, we propose the use of a machine learning approach during the process parameter development to predict the melt pool dimensions as a function of the P/V combination. This approach turns out to be useful in speeding up the identification of the printability map of the material and defining the conduction zone during the development phase. Moreover, a machine learning method allows for an accurate investigation of the most promising configurations in the P-V space, facilitating the optimization and identification of the P-V set with the highest productivity. This approach is validated by an experimental campaign carried out on samples of Inconel 718, and the effects of some additional parameters, such as the layer thickness (in the range of 30 to 90 microns) and the preheating temperature of the building platform, are evaluated. More specifically, the experimental data have been used to train supervised machine learning models for regression using the KNIME Analytics Platform (version 4.7.7). An AutoML (node for regression) tool is used to identify the most appropriate model based on the evaluation of R<sup>2</sup> and MAE scores. The gradient boosted tree model also performs best compared to Rosenthal’s analytical model. |
| first_indexed | 2024-03-08T15:11:55Z |
| format | Article |
| id | doaj.art-db6699b7adf9404cb6cb3f05089c32b7 |
| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-03-08T15:11:55Z |
| publishDate | 2023-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj.art-db6699b7adf9404cb6cb3f05089c32b72024-01-10T14:51:45ZengMDPI AGApplied Sciences2076-34172023-12-0114132810.3390/app14010328A Supervised Machine Learning Model for Regression to Predict Melt Pool Formation and Morphology in Laser Powder Bed FusionNiccolò Baldi0Alessandro Giorgetti1Alessandro Polidoro2Marco Palladino3Iacopo Giovannetti4Gabriele Arcidiacono5Paolo Citti6Department of Engineering Science, Guglielmo Marconi University, 00193 Rome, ItalyDepartment of Industrial, Electronic and Mechanical Engineering, Roma Tre University, 00146 Rome, ItalyDepartment of Engineering Science, Guglielmo Marconi University, 00193 Rome, ItalyBaker Hughes, Nuovo Pignone, 50127 Florence, ItalyBaker Hughes, Nuovo Pignone, 50127 Florence, ItalyDepartment of Engineering Science, Guglielmo Marconi University, 00193 Rome, ItalyDepartment of Engineering Science, Guglielmo Marconi University, 00193 Rome, ItalyIn the additive manufacturing laser powder bed fusion (L-PBF) process, the optimization of the print process parameters and the development of conduction zones in the laser power (P) and scanning speed (V) parameter spaces are critical to meeting production quality, productivity, and volume goals. In this paper, we propose the use of a machine learning approach during the process parameter development to predict the melt pool dimensions as a function of the P/V combination. This approach turns out to be useful in speeding up the identification of the printability map of the material and defining the conduction zone during the development phase. Moreover, a machine learning method allows for an accurate investigation of the most promising configurations in the P-V space, facilitating the optimization and identification of the P-V set with the highest productivity. This approach is validated by an experimental campaign carried out on samples of Inconel 718, and the effects of some additional parameters, such as the layer thickness (in the range of 30 to 90 microns) and the preheating temperature of the building platform, are evaluated. More specifically, the experimental data have been used to train supervised machine learning models for regression using the KNIME Analytics Platform (version 4.7.7). An AutoML (node for regression) tool is used to identify the most appropriate model based on the evaluation of R<sup>2</sup> and MAE scores. The gradient boosted tree model also performs best compared to Rosenthal’s analytical model.https://www.mdpi.com/2076-3417/14/1/328laser powder bed fusionmelt pool morphologypowder bed fusion–laser meltingPBF–LMInconel 718design for additive manufacturing |
| spellingShingle | Niccolò Baldi Alessandro Giorgetti Alessandro Polidoro Marco Palladino Iacopo Giovannetti Gabriele Arcidiacono Paolo Citti A Supervised Machine Learning Model for Regression to Predict Melt Pool Formation and Morphology in Laser Powder Bed Fusion Applied Sciences laser powder bed fusion melt pool morphology powder bed fusion–laser melting PBF–LM Inconel 718 design for additive manufacturing |
| title | A Supervised Machine Learning Model for Regression to Predict Melt Pool Formation and Morphology in Laser Powder Bed Fusion |
| title_full | A Supervised Machine Learning Model for Regression to Predict Melt Pool Formation and Morphology in Laser Powder Bed Fusion |
| title_fullStr | A Supervised Machine Learning Model for Regression to Predict Melt Pool Formation and Morphology in Laser Powder Bed Fusion |
| title_full_unstemmed | A Supervised Machine Learning Model for Regression to Predict Melt Pool Formation and Morphology in Laser Powder Bed Fusion |
| title_short | A Supervised Machine Learning Model for Regression to Predict Melt Pool Formation and Morphology in Laser Powder Bed Fusion |
| title_sort | supervised machine learning model for regression to predict melt pool formation and morphology in laser powder bed fusion |
| topic | laser powder bed fusion melt pool morphology powder bed fusion–laser melting PBF–LM Inconel 718 design for additive manufacturing |
| url | https://www.mdpi.com/2076-3417/14/1/328 |
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