SFA-AM - Strategic Focus Area Advanced Manufacturing
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MOCONT

MOnitoring and CONTrol of AM metal process
Additive manufacturing, also known as 3D printing, is a new technology that obliterates the geometrical limits of the produced workpieces and promises low running costs as compared to traditional subtractive manufacturing methods. Although it has high expectations in industry, the absence of a proper in situ and real-time quality monitoring and control prohibits the penetration of this technology into an extensive practice.
Today, most monitoring solutions for additive manufacturing (AM) process available on the market are based on visual analysis and temperature measurements. We believe that these technologies have many drawbacks. Hence, within this project, the team will take another very innovative approach to tackle the in situ and real-time quality control monitoring of the AM process. We want to combine various sensors (acoustic and optical), with Machine Learning (ML) and/or Artificial Intelligence (AI).

Scope of Research Activities
  • Getting a fundamental understanding of the AM process using selective laser melting (SLM), including the creation of defects
  • Elaboration of process maps and semi-empirical models for producing specific SLM samples
  • Characterizing the SLM samples in terms of samples quality and defects as well as material properties
  • Development and validation of a signal processing unit based on ML for defect classification
  • Development of algorithm for cracks localization due to residual stresses
  • Development of a universal model able to predict the defect creation

Key Challenges and Technical Problems to Solve
  • Classification of the type of defects with high confidence
  • Localization of cracks due to residual stresses
  • Ability to predict the creation of a defect in order to prevent the defect

Demonstrator
  • Method and device for pseudo real-time and in situ quality control monitoring of an SLM process able to classify the samples quality with 95% confidence and/or localize cracks.

Linked Scientific Publications

2022
  • Drissi-Daoudi, R., V. Pandiyan, R. Logé, S. Shevchik, G. Masinelli, H. Ghasemi-Tabasi, A. Parrilli and K. Wasmer (2022). "Differentiation of materials and laser powder bed fusion processing regimes from airborne acoustic emission combined with machine learning." Virtual and Physical Prototyping 17(2): 181-204.
  • Pandiyan, V., R. Drissi-Daoudi, S. Shevchik, G. Masinelli, T. Le-Quang, R. Logé and K. Wasmer (2022). "Deep transfer learning of additive manufacturing mechanisms across materials in metal-based laser powder bed fusion process." Journal of Materials Processing Technology 303: 117531.

2021
  • Pandiyan, V., R. Drissi-Daoudi, S. Shevchik, G. Masinelli, T. Le-Quang, R. Logé and K. Wasmer (2021). "Semi-supervised Monitoring of Laser powder bed fusion process based on acoustic emissions." Virtual and Physical Prototyping 16(4): 481-497.

2020
  • Pandiyan, V., R. Drissi-Daoudi, S. Shevchik, G. Masinelli, R. Logé and K. Wasmer (2020). "Analysis of time, frequency and time-frequency domain features from acoustic emissions during Laser Powder-Bed fusion process." Procedia CIRP 94: 392-397.
  • Shevchik, S., T. Le-Quang, B. Meylan, F. V. Farahani, M. P. Olbinado, A. Rack, G. Masinelli, C. Leinenbach and K. Wasmer (2020). "Supervised deep learning for real-time quality monitoring of laser welding with X-ray radiographic guidance." Scientific Reports 10(1): 3389.

2019
  • Shevchik, S. A., G. Masinelli, C. Kenel, C. Leinenbach and K. Wasmer (2019). "Deep Learning for In Situ and Real-Time Quality Monitoring in Additive Manufacturing Using Acoustic Emission." IEEE Transactions on Industrial Informatics 15(9): 5194-5203.
  • Wasmer, K., T. Le-Quang, B. Meylan and S. A. Shevchik (2019). "In Situ Quality Monitoring in AM Using Acoustic Emission: A Reinforcement Learning Approach." Journal of Materials Engineering and Performance 28(2): 666-672.

2018
  • Le-Quang, T., S. A. Shevchik, B. Meylan, F. Vakili-Farahani, M. P. Olbinado, A. Rack and K. Wasmer (2018). "Why is in situ quality control of laser keyhole welding a real challenge?" Procedia CIRP 74: 649-653.
  • Shevchik, S. A., C. Kenel, C. Leinenbach and K. Wasmer (2018). "Acoustic emission for in situ quality monitoring in additive manufacturing using spectral convolutional neural networks." Additive Manufacturing 21: 598-604.
  • Wasmer, K., T. Le-Quang, B. Meylan, F. Vakili-Farahani, M. P. Olbinado, A. Rack and S. A. Shevchik (2018). "Laser processing quality monitoring by combining acoustic emission and machine learning: a high-speed X-ray imaging approach." Procedia CIRP 74: 654-658.
Leading Principal Investigator
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Dr. Kilian Wasmer
Laboratory for Advanced Materials Processing, Empa


Project Consortium
  • Prof. Dr. Roland Logé
    Laboratory of Thermomechanical Metallurgy (LMTM), EPFL
  • Prof. Dr. Markus Strobl / Dr. Pavel Trtik
    Neutron Imaging and Activation (NIAG), PSI
  • Dr. Rolf Kaufmann
    X-Ray Center, Empa
  • Dr. François Fleuret
    Machine Learning Group,
    Idiap Research Institute
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© COPYRIGHT 2021. ALL RIGHTS RESERVED.
  • Home
  • Focus Areas
    • Focus Areas 2017-2020 >
      • Precision Free-Form Manufacturing
      • Printed Electronics
      • Sustainable Digital Manufacturing and Design
      • Sensing Technologies
      • Intelligent Systems and Advanced Automation
    • Focus Areas 2021-2024 >
      • Manufacturing Technologies
      • Functionality Integration
      • Sensing Technologies
      • Intelligent Systems and Advanced Automation
  • Projects
    • Projects Initial Program 2017-2020 >
      • Ceramic X.0
      • FUORCLAM
      • Powder Focusing
      • PREAMPA
      • FOXIP
      • CFRP-AM
      • SD4D
    • Projects Expansion Program 2017-2020 >
      • D-SENSE
      • MOCONT
      • Nano Assembly
      • SOL4BAT
    • Projects Program 2021-2024 >
      • AMYS
      • ClosedLoop-LM
      • DiPrintProtect
      • MANUFHAPTICS
      • Microfluidics
      • Multi-Mat
      • SCALAR
      • SMARTAM
  • Events
    • Annual Meetings >
      • Annual Review Meeting 2022
      • Annual Review Meeting 2021
      • Annual Review Meeting 2020
      • Annual Review Meeting 2019
      • Annual Review Meeting 2018
    • Industry Workshops >
      • Sensors
    • Other Events >
      • CERAMIC X.0 Workshop
      • Workshop 13 July 2020
      • Launch Event 13 Nov 2017
      • Workshop 6 July 2017
      • Workshop 17 Oct 2016
    • SAMCE
  • About
    • Steering Committee
    • Participating ETH Institutions
    • Calls & Selection >
      • Initial Program 2017-2020
      • Expansion Program 2017-2020
      • Continuation Program 2021-2024
  • Contact