Machine Learning for WAAM Melting Efficiency
Machine Learning for WAAM Melting Efficiency
https://doi.org/10.1007/s00170-022-08966-y
ORIGINAL ARTICLE
Received: 18 November 2021 / Accepted: 21 February 2022 / Published online: 2 March 2022
© The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature 2022
Abstract
Wire arc additive manufacturing (WAAM) appears as one of the most promising technologies due to its capacity to process
all types of materials used in welding, its high production rate, and capacity to process large geometries of particular inter-
est in the aeronautical industry. Since this technology is still under investigation, it is important to determine the efficiency
of the process; in this sense, the melting efficiency stands out not only as a parameter of interest in energy terms but also as
a measure of the stability of the process. For calculating melting efficiency, it is necessary to use tailored colorimeters or
apply models requiring specific dimensions that involve destructive testing. For this reason, in the development of this work,
the melting efficiency is evaluated through machine learning algorithms. Processing parameters such as wire diameter, wire
feed speed, travel speed, and net power are used to determine melting efficiency. In addition, a simplified analytical model
was developed to compare the results. The average melting efficiency analytically calculated was 44.56 ± 5.48%, while the
predicted value reaches a comparable value of 44.32 ± 4.79% obtained with the Gaussian process regressor, which shows
the highest accuracy. Moreover, the known relationship with travel speed was verified.
Keywords Melting efficiency · Wire arc additive manufacturing · Cold metal transfer · Machine learning
1 Introduction (powder bed fusion, PBF), and the second, where the mate-
rial is deposited directly in either powder or wires, called
Additive manufacturing (AM) has evolved substantially dur- directed energy deposition (DED) [3]. Wire arc additive
ing the last decades. It has transited from being a rapid pro- manufacturing (WAAM) is a DED technology that com-
totyping technology, mainly focused on polymer processing bines an electric arc as the heat source and a metal wire as
[1], to a technology capable of producing final functional feedstock, typically employing standard welding equipment.
parts and processing almost any type of material [2]. Within WAAM technology has many advantages compared to PBF
metal AM, two major technologies are distinguished, one processes. It has a higher deposition rate of up to 8 kg/h
where there is a bed of metallic powder and the content is [4], it does not always require a highly inert atmosphere
fused through a heat source, e.g., laser or electron beam [5], and it is possible to manufacture large and medium-
complex metal components [6] and process any alloy used
in welding [7].
* Jorge A. Ramos‑Grez In welding, it is common practice to use the heat input
[email protected]
to control process characteristics such as the cooling rate
Germán O. Barrionuevo and temperature gradient. The heat input is calculated as the
[email protected]
ratio of arc power to travel speed times the arc efficiency.
1
Department of Mechanical and Metallurgical Engineering, The arc efficiency considers the losses from the arc to the
School of Engineering, Pontificia Universidad Católica de environment. However, as Fuerschbach and Knorovsky [8]
Chile, Av. Vicuña Mackenna 4860, Macul, Santiago, Chile have pointed out, the heat input is insufficient to estimate the
2
Welding Engineering and Laser Processing Centre, Cranfield amount of metal that is actually melted. Conduction losses
University, University Way, Cranfield, Bedfordshire, UK through the material account for more than half the absorbed
3
University of Magallanes, Región de Magallanes y de la energy which goes into the material [9]. Moreover, the lat-
Antártica Chilena, Manuel Bulnes 01855, Punta Arenas, ter gets worse at low travel speed. These losses give origin
Chile
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Table 1 Experimental variables employed for the fabrication of mild 2.3 Machine learning algorithms
steel by cold metal transfer
Factor Symbol Min Max The core of the ML algorithms is the data. Therefore, Fig. 3
presents the statistical distribution of each variable and the
Wire diameter (mm) WD 0.8 1.2
histograms on the diagonal. The input parameters to train the
Wire feed speed (mm/s) WFS 28 222.5
algorithms were the wire diameter (WD), wire feed speed
Travel speed (mm/s) TS 1.66 25
(WFS), travel speed (TS), and nominal power (P). The out-
Power (kW) P 0.65 4.03
put parameter is the melting efficiency (ME) (Fig. 4). To
accurately predict melting efficiency in WAAM processes,
based on a controlled dip transfer mode mechanism (Fronius three types of the most potent ML regressors were employed,
CMT GmbH). All deposits were conducted on a 5-axis Trio which are detailed in the following sections.
Motion rig coupled with the Robacta Drive CMT welding
torch (Lincoln Power Wave) [13]. Seventy-five single layer 2.3.1 Gaussian process regressors
deposits were fabricated, where the wire diameter, wire feed
speed, and travel speed were controlled while bead width, bead Gaussian process regressor (GPR) is a stochastic method
height, and energy were quantified. Furthermore, the cross- based on statistical learning and Bayesian theory that meas-
sectional area was determined by optical micrographs. The ures the similarity between points using a kernel function to
range of processing parameters is listed in Table 1. predict the value for an unseen point from the training data
[37]. GPR works well on small datasets and can provide
2.2 Melting efficiency evaluation uncertainty measurements on the predictions [38].
For assessing melting efficiency, Eq. (4) was applied, the 2.3.2 Extreme gradient boosting regressor
source efficiency was held constant ( 𝜂s = 0.9 ). In cases
where it is difficult to assess the cross-section area, it is pos- Extreme gradient boosting regressor (XGBR) is an ensemble
sible to replace Aw with the product between layer height boosting method, which predicts the desired outcome based
(H) and wall width (W), as they show a high coefficient of on a forward stage-wise fashion [33]; it allows the optimiza-
correlation (R2 = 0.9797) (Fig. 2). Moreover, a coefficient tion of arbitrary differentiable loss functions [38]. It uses a
(𝜁 = 0.87) is added to Eq. (4) in order to improve the model regularized model formalization to control overfitting, which
accuracy and increase its precision. Therefore, the melting gives it better performance.
efficiency can be calculated using Eq. (7):
2.3.3 Multi‑layer perceptron
𝜁.𝛾 ⋅ v ⋅ H ⋅ W
𝜂m = (7)
𝜂s ⋅ P Multi-layer perceptron (MLP), commonly known as artifi-
cial neural network (ANN), is based on the perceptron as an
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Fig. 3 Scatter matrix to show a possible correlation between process parameters and melting efficiency
operational unit trained using backpropagation; therefore, it uses and attempt to find the optimal values that maximize the
the square error as a loss function output set of continuous val- coefficient of determination (R2). The ranges of explored
ues. MLP determines a function y = f (x;𝜃) and learns the value hyperparameters are listed in Table 2.
of the parameters 𝜃 that result in the best approximation [39]. The dataset assembled with the experimental data was
GPR, XGBR, and MLP were all trained and tested. randomized and then split into training (80%) and testing
The dataset was assembled from the experimental results (20%) portions. Before initiating the training process, the
(Fig. 3). In order to achieve the highest accuracy, the dataset was scaled using zero mean and unit variance. The
hyperparameters of each ML algorithm were tuned by ML algorithms employed to assess the melting efficiency
applying random search optimization. This procedure were executed in Google Colaboratory (Colab) environ-
automatically examines the hyperparameter search space ment using Scikit-learn and XGBoost libraries.
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2.4 Evaluation of the precision of machine learning into the data, and the model can improve the usefulness of a
algorithms predictive model on the estimations achieved.
where R2 is the coefficient of determination, MSE is the 3.2 Analytical melting efficiency results
mean squared error, and MAE is the mean absolute error.
This index of merit (IM) evaluates the accuracy of the According to the methodology explained in Sect. 2.2, Eq. (7)
predictions; as the magnitude of the index approaches zero, shows good agreement with the conventional model depicted
the maximum predicting accuracy is achieved. This metric in Eq. (4). A 𝜂m of 44.56 ± 5.48% was obtained using Eq. (4),
is beneficial when all metrics present similar results. while 𝜂m = 44.47 ± 6.47% is reported when applying Eq. (7).
Once identified which algorithm presents the higher Therefore, the use of the height and width of the WAAM
accuracy (lower IM), feature importance analysis (FIA) deposit appears as a good alternative to replace the pen-
was employed. FIA assigns a score to input features based etration area (A1), and the energy consumed in melting the
on how useful they are at predicting a target variable ( 𝜂m ). deposited material (A2). The obtained results are in agree-
Moreover, FIA provides scores that help us obtain insight ment with the results reported by DuPont and Marder [42].
Furthermore, it is common to report the melting efficiency
as a function of the travel speed; thus, Fig. 6 shows that the
melting efficiency increases with increasing travel speed.
Table 2 Hyperparameter ranges employed in random search optimi- Equations (4), (5), and (7) were employed to assess the melt-
zation
ing efficiency in WAAM analytically.
ML algorithm Hyperparameter ranges
GPR Noise level α: [0.001, 0.1, 1, 10] 3.3 Machine learning melting efficiency results
Number of optimizers: [5, 10, 20]
XGBR Number of estimators: [100, 1000, 10000] The obtained hyperparameters that maximize the accuracy
Maximum depth: [5, 10, 20] by random search optimization are reported in Table 3.
Learning rate: [0.1, 0.01, 1e-3] Gaussian process regressor (GPR), extreme gradi-
MLP Hidden layers: [5, 8, 10] ent boosting regressor (XGBR), and multi-layer per-
Activation function: [“relu,” “tanh”]
Solver: [“lbfgs,” “sgd,” “adam”] ceptron (MLP) algorithms were applied to predict the
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melting efficiency during WAAM. All algorithms show and MLP present similar metrics, but MLP presents a
similar predictions, GPR reports a melting efficiency higher index of merit, therefore, lower accuracy.
of 44.32 ± 4.79%, XGBR 44.69 ± 4.62%, and MLP
44.12 ± 4.80%. The dispersion of these results is due in part
to the range of travel speed involved in the CMT experi- Table 3 Hyperparameters that provide the highest accuracy of each
ments. The obtained metrics during the cross-validation ML algorithm
and testing are reported in Table 4. ML algorithm Hyperparameters
Cross-validation provides a practical evaluation of the
GPR Noise level α = 0.001
models’ capability to predict new data and face common Number of optimizers = 40
problems as underfitting or overfitting. For the melting XGBR Number of estimators = 100
efficiency evaluation, all the examined algorithms pro- Maximum depth = 10
vide similar metrics. Nonetheless, GPR achieves a higher Learning rate = 0.1
coefficient of determination, which explains how well the MLP Hidden layers = 5
model replicates the observed results and presents the Activation function = relu
Solver = lbfgs
same value for MAE with the XGBR algorithm. XGBR
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GPR obtains the lowest IM and reports the highest R2 in Fig. 9. GPR and MLP algorithms converge to the maxi-
and the lowest error metrics about the set employed for mum melting efficiency value (≈ 51%); on the other hand,
testing evaluation. All the algorithms show good accuracy XGBR reports a melting efficiency near the average (44.8%).
for predicting melting efficiency in WAAM. Figure 7 shows Therefore, GPR and MLP capture the essence of the melting
the performance evaluation of each ML algorithm. The efficiency evaluation; they can reproduce the observed trend
training dataset is plotted in black dots and different colors in Fig. 6 and the model developed by Wells [14].
in the testing dataset by each algorithm. The predicted During the WAAM process planning, it is worth noting
melting efficiency corresponds to the vertical axes, while that although the melting efficiency increases with increasing
the horizontal axes show the measured melting efficiency. travel speed, there is a threshold where the heat input only
Figure 8 shows the feature-importance analysis, where melts the feedstock but does not melt the substrate, caus-
power (P) scores the highest value, 72.74%. Therefore, the ing delamination. Moreover, a roughness increase has been
nominal power represents the main factor for the prediction reported while increasing travel speed or decreasing power
model. Travel speed (TS) and wire feed speed (WFS) show due to a lower melting efficiency [25]. Experimentally, it has
feature importance of 11.56 and 10.47%, respectively. The wire been found that the power with which there is greater melting
diameter practically does not influence the model predictability. efficiency is around 2.6 kW. Thus, a linear energy density of
In order to assess the behavior of the ML algorithms, around 110 J/mm is recommended for processing carbon-
an average set of processing parameters was selected manganese steel. Furthermore, an inverse relationship has
(WD = 0.8 mm, WFS = 98 mm s−1, P = 2245 W); the melting been reported between travel speed, melt pool depth, and
efficiency evaluation is reported as a function of travel speed width, and a direct relationship with heat input [10, 43].
Fig. 7 Scatter plot for accuracy evaluation of the GPR performance in the melting efficiency prediction
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Fig. 8 Feature importance analysis of the processing parameters in the melting efficiency prediction model
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4 Conclusions References
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