Transferability of Temperature Evolution of Dissimilar Wire-Arc Additively Manufactured Components Using Finite Element Simulation through Machine Learning

Abstract

Wire-arc additive manufacturing (WAAM) is a promising industrial production technique. Without optimization, inherent temperature gradients can cause powerful residual stresses and microstructural defects. There is therefore a need for data-driven methods allowing real-time process optimization for WAAM. This study focuses on machine learning (ML)-based prediction of temperature history for WAAM-produced aluminum bars with different geometries and process parameters, including bar length, number of deposition layers, and heat-source movement speed. Finite element (FE) simulations are used to provide training and prediction data. The ML models are based on a simple multilayer perceptron (MLP) and performed well during baseline training and testing, giving a testing mean absolute percentage error (MAPE) of less than 0.7% with an 80/20 train–test split, with low variation in model performance. When using the trained models to predict results from FE simulations with greater length or number of layers, the MAPE increased to an average of 3.22% or less, with greater variability. In the cases of greatest difference, some models still returned a MAPE of less than 1%. For different scanning speeds, the performance was worse, with some outlier models giving a MAPE of up to 14.91%. This study demonstrates the transferability of temperature history for WAAM with a simple MLP approach.

Transferability of Temperature Evolution of Dissimilar Wire-Arc Additively Manufactured Components Using Finite Element Simulation through Machine Learning