Metal additive manufacturing (AM) works on the principle of consolidating feedstock material in layers towards the fabrication of complex objects through localized melting and resolidification using high-power energy sources. Powder bed fusion and directed energy deposition are two widespread metal AM processes that are currently in use. During layer-by-layer fabrication, as the components continue to gain thermal energy, the melt pool geometry undergoes substantial changes if the process parameters are not appropriately adjusted on-the-fly. Although control of melt pool geometry via feedback or feedforward methods is a possibility, the time needed for changes in process parameters to translate into adjustments in melt pool geometry is of critical concern. A second option is to implement multi-physics simulation models that can provide estimates of temporal process parameter evolution. However, such models are computationally near intractable when they are coupled with an optimization framework for finding process parameters that can retain the desired melt pool geometry as a function of time. To address these challenges, a hybrid framework involving machine learning-assisted process modeling and optimization for controlling the melt pool geometry during the build process is developed and validated using experimental observations. A widely used 3D analytical model capable of predicting the thermal distribution in a moving melt pool is implemented and, thereafter, a nonparametric Bayesian, namely, Gaussian Process (GP), model is used for the prediction of time-dependent melt pool geometry (e.g., dimensions) at different values of the process parameters with excellent accuracy along with uncertainty quantification at the prediction points. Finally, a surrogate-assisted statistical learning and optimization architecture involving GP-based modeling and Bayesian Optimization (BO) is employed for predicting the optimal set of process parameters as the scan progresses to keep the melt pool dimensions at desired values. The results demonstrate that a model-based optimization can be significantly accelerated using tools of machine learning in a data-driven setting and reliable a priori estimates of process parameter evolution can be generated to obtain desired melt pool dimensions for the entire build process.
Prediction of thermoacoustic instabilities is a critical issue for both design and operation of combustion systems. Sustained high-amplitude pressure and temperature oscillations may cause stresses in structural components of the combustor, leading to thermomechanical damage. Therefore, the design of combustion systems must take into account the dynamic characteristics of thermoacoustic instabilities in the combustor. From this perspective, there needs to be a procedure, in the design process, to recognize the operating conditions (or parameters) that could lead to such thermoacoustic instabilities. However, often the available experimental data are limited and may not provide a complete map of the stability region(s) over the entire range of operations. To address this issue, a Bayesian nonparametric method has been adopted in this paper. By making use of limited experimental data, the proposed design method determines a mapping from a set of operating conditions to that of stability regions in the combustion system. This map is designed to be capable of (i) predicting the system response of the combustor at operating conditions at which experimental data are unavailable and (ii) statistically quantifying the uncertainties in the estimated parameters. With the ensemble of information thus gained about the system response at different operating points, the key design parameters of the combustor system can be identified; such a design would be statistically significant for satisfying the system specifications. The proposed method has been validated with experimental data of pressure time-series from a laboratory-scale lean-premixed swirl-stabilized combustor apparatus.
This paper proposes a machine learning–based multifidelity modeling (MFM) and information-theoretic Bayesian optimization approach where the associated models can have complex discrepancies among each other. Advantages of MFM-based optimization over a single-fidelity surrogate, specifically under complex constraints, are discussed with benchmark optimization problems involving noisy data. The MFM framework, based on modeling of the varied fidelity information sources via Gaussian processes, is augmented with information-theoretic active learning strategies that involve sequential selection of optimal points in a multiscale architecture. This framework is demonstrated to exhibit improved efficiency on practical engineering problems like high-dimensional design optimization of compressor rotor via implementing its multiscale architecture and calibration of expensive microstructure prediction model. From the perspective of the machine learning–assisted design of multiphysics systems, advantages of the proposed framework have been presented with respect to accelerating the search of optimal design conditions under budget constraints.
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