Transfer learning in laser-based additive manufacturing: Fusion, calibration, and compensation
Date of Degree
Original embargo terms
Complete embargo for 1 year||12/15/2021
Dissertation - Open Access
Doctor of Philosophy
James Worth Bagley College of Engineering
Department of Industrial Engineering
The objective of this dissertation is to provide key methodological advancements towards the use of transfer learning in Laser-Based Additive Manufacturing (LBAM), to assist practitioners in producing high-quality repeatable parts. Currently, in LBAM processes, there is an urgent need to improve the quality and repeatability of the manufacturing process. Fabricating parts using LBAM is often expensive, due to the high cost of materials, the skilled machine operators needed for operation, and the long build times needed to fabricate parts. Additionally, monitoring the LBAM process is expensive, due to the highly specialized infrared sensors needed to monitor the thermal evolution of the part. These factors lead to a key challenge of improving the quality of additively manufactured parts, because additional experiments and/or sensors is expensive. We propose to use transfer learning, which is a statistical technique for transferring knowledge from one domain to a similar, yet distinct, domain, to leverage previous non-identical experiments to assist practitioners in expediting part certification. By using transfer learning, previous experiments completed in similar, but non-identical, domains can be used to provide insight towards the fabrication of high-quality parts. In this dissertation, transfer learning is applied to four key domains within LBAM. First, transfer learning is used for sensor fusion, specifically to calibrate the infrared camera with true temperature measurements from the pyrometer. Second, a Bayesian transfer learning approach is developed to transfer knowledge across different material systems, by modelling material differences as a lurking variable. Third, a Bayesian transfer learning approach for predicting distortion is developed to transfer knowledge from a baseline machine system to a new machine system, by modelling machine differences as a lurking variable. Finally, compensation plans are developed from the transfer learning models to assist practitioners in improving the quality of parts using previous experiments. The work of this dissertation provides current practitioners with methods for sensor fusion, material/machine calibration, and efficient learning of compensation plans with few samples.
Francis, Jack, "Transfer learning in laser-based additive manufacturing: Fusion, calibration, and compensation" (2020). Theses and Dissertations MSU. 4773.