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Time delay compensation in high-speed diamond turning of freeform surface using independent fast tool servo with a long stroke

Hashimoto T., Yan J.

Precision Engineering 93 515 - 527 2025年05月

ISSN 01416359

The demand for wearable device applications has continuously grown in recent years, especially with the significant rise of augmented and virtual reality technologies. Freeform optics plays a crucial role in these devices by enhancing optical performance, shortening the light path, and reducing the weight, all while allowing for smaller, lighter systems with higher efficiency. The independent fast tool servo (FTS)-based diamond-turning method stands out as a highly effective technique for fabricating freeform shapes with high accuracy and productivity. However, microsecond-order time delays occur within the system, significantly impacting form accuracy as machining speeds increase. This study explores the sources of form errors in freeform surface fabrication associated with the FTS diamond-turning process, with particular attention to the effects of clocking angle errors caused by the time delay. These errors were found to greatly affect form accuracy, especially at higher machining speeds. The FTS position data were analyzed, and time delays under various operational conditions due to servo control were confirmed. To precisely identify the extent of the time delay, a cylindrical surface was machined under high-speed conditions, and the clocking angle error was measured using a non-contact chromatic probe. Results showed that time delays originating from the machine platform had a significant effect on form accuracy. By accurately identifying and compensating for these time delays, the clocking angle error was eliminated. To validate the effectiveness of the time-delay compensation strategy, a cylindrical freeform surface was machined after the compensation, and the clocking angle error was minimized down to 0.00014° evaluated by on-machine measurement. The form accuracy of the freeform machining result after compensation was achieved at 0.85 μm PV. This study establishes a methodology for identifying and compensating for time delays in an independent FTS system, contributing to improved form accuracy in freeform optics fabrication.

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Evolution of surface and subsurface properties of Zr-4 alloy under the combined effects of laser heat treatment and laser gas nitriding: Microscopic morphology, chemical composition, and mechanical behavior

Xu P., Qian Y., An H., Guo H., Zhang Z., Jiang M., Huang H., Yan J.

Journal of Materials Processing Technology 339 2025年03月

ISSN 09240136

Zr-4 alloy, extensively employed as cladding in nuclear reactor fuel rods, stands as the foremost line of defense for reactor safety. Given its susceptibility to defects such as micro-pores during casting and its long-term exposure to extreme conditions during practical service processes, enhancing the surface and subsurface properties of Zr-4 alloy is essential. Herein, a nanosecond pulsed laser is used to irradiate the Zr-4 alloy in a nitrogen environment to investigate the evolution of its surface and subsurface properties under the combined effects of laser heat treatment and laser gas nitriding. The experimental results reveal a remarkable augmentation in surface hardness and scratch resistance of the Zr-4 alloy after laser irradiation. Notably, the hardness of the laser-irradiated surface obtained with a laser power of 23.0 W and a scanning speed of 150 mm/s reaches 19.10 GPa, which is more than 7 times higher than that of the untreated surface (2.37 GPa). These improvements are attributed to the synergistic effects of the introduction of hard ZrN phase, the reduction of subsurface porosity, and grain refinement. This study demonstrates a promising approach for significantly improving the mechanical properties of Zr-4 alloy, holding considerable practical significance for its applications in the nuclear energy industry and other relevant fields.

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Coupled SPH-FEM Simulation Model to Analyze the Mechanism of Single Particle Impact in Abrasive Waterjet Machining

Abdelhameed Y., Maher I., Yan J., El-Hofy H., Hassan M.A.

Tribology in Industry 47 （ 1 ） 77 - 91 2025年03月

ISSN 03548996

Studying single particle impact is crucial to understanding the erosion mechanism in abrasive waterjet machining (AWJM). In this paper, the finite element method (FEM) and smoothed particle hydrodynamics (SPH) were combined to investigate the mechanism of single particle impact under the waterjet influence. The particle (garnet) and workpiece (Al 7075-T6) were represented by FEM, while the waterjet was discretized using SPH. Linear elasticity and the Johnson-Cook (JC) model were selected to model the abrasive and workpiece materials, respectively. The simulation was conducted in ABAQUS where the effects of particle shape, position, and impact angle on material removal were investigated. The results of the developed model revealed that the erosion mechanism and mechanics significantly differed when considering the waterjet effect. This was primarily attributed to the dynamic phenomena resulting from the waterjet impact, including stagnation zone and drag forces. It was found that the impact angle corresponding to maximum erosion depended on the particle shape and radial position within the jet stream. The presented model has proved its capability since it offers a novel perspective on the single particle impact mechanism by incorporating the realistic dynamic phenomena accompanying the impact in AWJM.

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Fabrication of microcone arrays on Ti6Al4V by nanosecond laser nitriding

Zhang H., Wang B., Yang Z., Zhang H., Zhang Z., Huang H., Yan J.

International Journal of Mechanical Sciences 287 2025年02月

ISSN 00207403

The application of titanium alloys still faces some challenges such as relatively low hardness and insufficient wear resistance. Nanosecond pulsed laser irradiation in a nitrogen atmosphere has proven to be effective for fabricating micro/nano structures on titanium alloys, enhancing surface hardness and wear resistance. However, micro/nano structures produced by line-by-line laser scanning often exhibit directional differences and surface defects such as re-deposited particles and pores. Herein, vertically crossed laser scanning in a nitrogen atmosphere was employed to address the directional difference, enabling the simultaneous fabrication of microcone arrays and nitriding layers on Ti6Al4V surface. To eliminate the surface defects on the microcone structure, laser surface finishing via defocused scanning was performed, followed by morphological analysis, bonding force evaluation, and tribological performance testing. The results showed that the area percentage of re-deposited particles on the laser-finished microcone array surface decreased from 24 % to 5 %. The bonding force of the nitriding layer was assessed using linear loading scratch tests, and the highest value of 69 N was obtained. To investigate the wear resistance of the laser-finished microcone array surface, friction and wear tests were performed. From 25 °C to 600 °C, nearly no wear grooves were observed on the tested surfaces, demonstrating excellent high-temperature wear resistance. The wear mechanism was mainly related to the cutting action of the microcone structures on the counterpart ball. This study advances the fabrication of micro/nano structures and simultaneous nitriding on titanium alloys, demonstrating the significant potential for practical applications as surface contact materials.

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Nanoindentation behavior of the laser-repaired CoCrFeNiV high-entropy alloy

Wang C., Huang W., Yi C., Jiang M., Huang H., Yan J.

Intermetallics 177 2025年02月

ISSN 09669795

High-entropy alloys (HEAs) are solid-solution alloys composed of multiple elements, exhibiting excellent mechanical properties. The unique plastic deformation mechanism induced by their specific solid solution structures has attracted considerable attention but remains incompletely understood, particularly at the micro-scale. In this study, the surface morphology, chemical composition, and microstructures of CoCrFeNiV HEA before and after laser remelting repair were investigated. Nanoindentation testing was employed to characterize the surface hardness and creep behavior of the repaired surface. The distribution of surface hardness before and after laser remelting, as well as the indentation creep behavior under different loads, were studied. The mechanism of indentation creep on the repaired surface was discussed and analyzed. The effect of microstructures of HEAs, including precipitated phases and sub-grain boundaries, on dislocation-dominated micro-scale plastic deformation was elucidated by the transmission electron microscope (TEM). This study contributes to an in-depth understanding of the creep behavior and micro-scale deformation mechanisms in HEAs.

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Special Issue: The State-of-the-Art in Japanese Manufacturing Research

Kakinuma, Y; Matsubara, A; Matsumura, T; Sugita, N; Suzuki, N; Takahashi, S; Yan, JW

JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME 147 （ 1 ） 2025年01月

ISSN 1087-1357

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Femtosecond Pulsed Laser Machining of Fused Silica for Micro-Cavities With Sharp Corners

Brinkmann, M; Qian, YF; Huang, H; Yan, JW

JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME 147 （ 1 ） 2025年01月

ISSN 1087-1357

Fused silica is an important material for applications requiring high temperature resistance, low thermal expansion coefficient, and excellent optical properties. The machining of micro-cavities on fused silica surfaces is of particular interest for micro-fluidic manipulation and miniaturization of high-quality optical waveguides, etc., but it still remains technically challenging for traditional manufacturing techniques. In the present study, machining of square cornered semienclosed micro-cavities on fused silica surfaces by femtosecond laser has been investigated experimentally. The effects of laser machining conditions including laser power, laser scanning speed, laser incidence angle, and laser-off delay time on the sidewall slope and bottom surface roughness of the micro-cavities were comprehensively investigated. The results indicated that laser power played an important role in determining the sidewall slope of the micro-cavity, while the laser scanning speed had a significant influence on the bottom surface roughness and subsurface damage. Furthermore, the sidewall slope of the micro-cavity was linearly increased as the laser incidence angle increases. By using a laser incidence angle of 10 deg and a laser-off delay time of 280 ms, a micro-cavity with sidewall slopes close to right angles (90 deg) was fabricated. This study demonstrates that femtosecond laser machining is an effective method for fabricating sharp cornered micro-cavities in fused silica, and the appropriate selection of laser machining conditions based on practical application scenarios is important.

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Subsurface amorphization-induced ultrasmooth and ultrahard surface during the diamond turning of polycrystalline pure copper

Wang S., He C., Wang Z., Yan J.

Materials and Design 249 2025年01月

ISSN 02641275

Previous simulations indicated that pure metals can be amorphized during diamond turning. However, no pure metal has been successfully amorphized during this procedure to date. Herein, a comprehensive study on the surface formation mechanism was performed by examining the surface finish and subsurface variation characteristics. Polycrystalline pure copper was selected as the working material. In this study, the amorphization phenomenon and lattice structure transformations (from face-centred cubic to hexagonal close-packed and monoclinic structures) of pure copper were observed. The amorphization and phase transformation inside the working material depended on the tool nose radius being large, the cutting edge being sharp, and the feed rate being low. By using a large-nose-radius (10 mm) diamond tool with a sharp cutting edge (10.3 nm) at a low feed rate (0.5 μm/rev), an ultrasmooth and ultrahard surface with a 0.61 nm roughness Sa and 5.0 GPa nanohardness was achieved. Molecular dynamics simulations revealed that the high shear strain was responsible for the amorphization and lattice structure transformation during pure copper diamond turning. The findings of this study were considered critical for generating an amorphous subsurface layer in a pure metal and for achieving a ultrasmooth and ultrahard surface using single-point diamond turning.

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Nanosecond Laser Nanopatterning of Highly Ordered Nanodot Arrays on Silicon Surface: Breaking the Monopoly of Femtosecond Lasers

Qian Y., An X., An H., Huang H., Geng Y., Zhang Z., Huang W., Yan J.

Laser and Photonics Reviews 19 （ 11 ） 2025年

ISSN 18638880

Laser nanopatterning is an effective strategy to manipulate the surface properties of materials. One of the glaring restrictions is that the fabrication of long-range ordered nanostructures typically relies on ultrafast lasers, especially femtosecond lasers, while the insurmountable thermal effects associated with the longer pulse durations of nanosecond lasers are deeply considered to be the nemesis of this scenario. Herein, for the first time, a nanosecond laser-based nanopatterning technique for fabricating highly ordered nanodot arrays on the monocrystalline silicon surface through a remarkably straightforward process is proposed. The mechanism involves Marangoni flow-assisted low-threshold oxidation of monocrystalline silicon induced by nanosecond laser, along with a domino-like growth process of nanodots driven by optical near-field enhancement. Finite-difference-time-domain (FDTD) simulations provide insight into the underlying origin of nanosecond laser-induced nanodot arrays. The prepared large-area nanodot arrays demonstrate a range of functionalities, including the manipulation of light reflection and diffraction, structural color, and surface-enhanced Raman scattering (SERS). The present study challenges the established view that the pronounced thermal effects associated with the long pulse durations of nanosecond lasers are incompatible with high-precision nanopatterning, which opens new avenues for research into laser-matter interactions.

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Statistical modeling and optimization of ultrasonic vibration assisted end grinding of alumina ceramics

Mansour M.M., Maher I., Nassef M.G.A., El-Hofy H., Yan J., Khairaldien W.M.

International Journal on Interactive Design and Manufacturing 19 （ 10 ） 7283 - 7301 2025年

ISSN 19552513

Alumina is an advanced ceramic material that has numerous applications in dentistry and medicine. Ultrasonic-assisted end grinding proved to be one of the most successful and efficient ceramic processing techniques. However, the current state of the art in UAEG of alumina is mostly limited to finishing operations with low material removal rates. In this paper, UAEG is investigated to find the optimum grinding conditions of roughing operations of alumina ceramics. Response Surface Methodology was employed to study all combined effects of the spindle speed, feed rate, depth of cut, and vibration amplitude on the MRR, grinding forces and surface roughness. The surface morphology of the ground surface and the magnitude of the resultant grinding forces were recorded and analyzed for each test. The results showed that the vibration amplitude has the most influential effect on surface roughness with a contribution of 32.08%, while the grinding force is most affected by depth of cut (32.02%). The spindle speed of 9500 rpm, feed rate of 900 mm/min, depth of cut of 47 µm, and vibration amplitude of 2.6 µm are found to be the optimum machining parameters that maximize MRR and minimizing the grinding force and surface roughness.

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Surface finishing by shape-adaptive processes

Yan J., Mullany B., Beaucamp A., Meyer D., Sugita N.

CIRP Annals 74 （ 2 ） 1019 - 1045 2025年

ISSN 00078506

Complex surfaces are increasingly used in optics, biomedical devices, and aerospace industries. Additive manufacturing and five-axis milling can produce complex shapes, but additional finishing processes are needed to meet the surface quality demands. This keynote paper reviews shape-adaptive finishing processes that enable uniform surface quality improvement without altering the shape. Key factors affecting shape adaptability, processing efficiency, and material applicability are analyzed and optimal process selection strategies for finishing complex surfaces are discussed. Future possibilities and research topics in this area, including process modeling/simulation, digital twin, surface/subsurface metrology, functionality evaluation, and applications of advanced robotics and artificial intelligence, are outlined.

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Finite element analysis of material removal in AWJM using different material models and spatial distributions for garnet abrasives

Abdelhameed Y., Maher I., Yan J., El-Hofy H., Hassan M.A.

International Journal of Machining and Machinability of Materials 27 （ 2 ） 121 - 144 2025年

ISSN 17485711

Garnet, the most widely used abrasive material in abrasive waterjet machining (AWJM), presents challenges in modelling its behaviour. Therefore, a finite element (FE) model was proposed to analyse the effect of using different material models and spatial distributions for garnet on the erosion behaviour of Al 7075-T6. Three popular material models were considered for garnet, including rigid, linear elastic, and tensile failure models, in addition to the Johnson-Holmquist (JH2) model. These four models were tested and compared for single and multiple particle impact under different waterjet pressures, abrasive mesh sizes, and impact angles. Furthermore, the effect of particle spatial distribution within the jet pass was examined. The model results demonstrated that using different material models for garnet significantly controls the erosion behaviour in AWJM. In addition, the radial distribution of the abrasive particles critically affected the erosion process and kerf geometry, while the axial distribution insignificantly influenced the erosion rate.

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Laser-Induced Visualization of Latent Fingerprints on Metal Surfaces

Guo H., Qian Y., An H., Xu P., Wang X., Huang H., Zhang Z., Jiang M., Yan J.

Small 21 （ 38 ） 2025年

ISSN 16136810

Latent fingerprints (LFPs) are pivotal evidence in criminal investigations, yet their direct observation poses inherent challenges, necessitating advanced visualization techniques. Here, an innovative one-step laser-based methodology is presented for the rapid and accurate visualization of LFPs on metal surfaces. Gray value analysis is utilized to compare the optical contrast between the ridges and valleys of original and visualized fingerprints. Additionally, an orientation field method is employed to evaluate the texture quality of visualized fingerprints. The results demonstrate that laser irradiation significantly enhances the recognizability and pattern fidelity of LFPs by inducing differential oxide deposition: ridges, enriched in skin secretions, exhibit reduced oxide accumulation compared to valleys, thereby amplifying ridge-valley optical contrast. Furthermore, the visualized fingerprints exhibit excellent resistance to abrasion. Importantly, this method demonstrates broad applicability across surfaces with varying roughness levels and diverse metal types. This study establishes a robust and versatile tool for the rapid and accurate visualization of LFPs, offering transformative potential for forensic investigations.

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Manipulating Wetting State of CFRP via One-Step Laser Micro/Nanostructuring

An H., Qian Y., Xu X., Guo H., Wang B., Zhang Z., Jiang M., Huang H., Yan J.

Small 21 （ 44 ） 2025年

ISSN 16136810

The wetting state is a fundamental property of a material surface, yet achieving precise control over this property remains a formidable challenge. Mastery of wetting behavior can impart tailored functionalities to surfaces, such as liquid repellency, anti-fouling, and directional liquid transport. Despite the potential benefits, strategies for rapid and reliable modulation of various wetting states have remained elusive until now. In this study, an innovative one-step laser-based strategy that enables precise and rapid manipulation of surface wetting states on carbon fiber reinforced plastic (CFRP) is presented. This approach allows for the creation of hydrophilic surfaces characterized by the Wenzel state, hydrophobic surfaces with a mixed Cassie-Baxter/Wenzel state, and robust superhydrophobic surfaces featuring a stable Cassie-Baxter state. The realization of a stable Cassie-Baxter state stems from the concurrent formation of hierarchical micro/nanostructures and the enrichment of low surface energy components. Critically, the resulting superhydrophobic CFRP surfaces with the Cassie-Baxter state exhibit exceptional stability, minimized adhesion, and superior anti-icing and de-icing properties. These findings provide both fundamental insights and a practical platform for the rapid development of non-wetting, multifunctional surfaces, significantly expanding the applicability of CFRP across diverse engineering domains.

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Influence of crystallinity on micro-nano structure response of Zr-based alloys treated by nanosecond laser

Qian Y., Hong J., Jiang M., Zhang Z., Huang H., Yan J.

Optics and Lasers in Engineering 183 2024年12月

ISSN 01438166

Understanding the processes and mechanisms of laser-matter interaction is fundamental to the treatment of materials by using laser-based methods, but it is quite challenging because the response of matter to laser irradiation is influenced by many factors, especially the intrinsic properties of the matter. In this study, the influence of crystallinity on micro-nano structure response of Zr-based alloys (Zr41.2Ti13.8Cu12.5Ni10Be22.5) treated by nanosecond laser is investigated. The microscopic topographies and geometrical dimensions of the laser-induced micro-nano structures formed on the surface of Zr-based alloys with different crystallinity have been explored and compared. The experimental results indicate that the microstructural transformation between micro-concave and micro-convex is observed for both amorphous and crystallized Zr-based alloys, i.e., independent of the arrangement of the internal atomic structure. The geometrical dimensions of the laser-induced micro-nano structures and the critical peak laser power intensity required for the microstructural transformation are different, which can be attributed to the difference in thermal conductivity. Inspired by laser-induced micro-convex, a point-by-point laser patterning technique has been proposed for highly efficient and flexible preparation of micro-nano patterns. Importantly, this patterning technique exhibits ultra-high processing efficiency with a material accumulation rate of more than 1012 μm3/s. This work paves an avenue for understanding the laser-matter interaction and is expected to facilitate the advanced functional applications of Zr-based alloys in many fields.

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Surface morphology formation and subsurface microstructure evolution of zirconia in ultrasonic vibration-assisted burnishing

Huang W., Tsuchida T., Yan J.

Journal of Materials Processing Technology 333 2024年12月

ISSN 09240136

Yttria-stabilized zirconia (YSZ) is an outstanding ceramic material with applications in dentistry, biomedical, and mechanical device, where a smooth and durable surface is required. This study employed ultrasonic vibration-assisted burnishing (UVB) to enhance the surface hardness of YSZ while simultaneously reducing its roughness. The surface topography formation, subsurface microstructure evolution, and surface hardness change of YSZ were investigated. It was found that a smooth surface with an average roughness (Ra) of 0.12 μm was achieved using UVB, representing 67.6 % reduction in surface roughness from the original sintered surface, which is attributed to the burnishing-to-cutting phenomenon during the processing. The UVB-induced compression and material densification prevented the formation of the monoclinic phase during the processing of YSZ. Grain refinement and crystal lattice distortion occurring in the subsurface layer led to an increase in surface hardness, reaching up to 19.7 % higher than that of the original sintered surface. Moreover, the UVB-processed surface demonstrated a high resistance to mechanical impacts, effectively inhibiting the tetragonal-to-monoclinic phase transformation in indentation testing. These findings demonstrate that UVB is an effective approach for enhancing the surface and subsurface properties of the material.

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Achieving ultra-low wear of Ti6Al4V alloy by introducing a sinusoidal nitriding layer via nanosecond pulsed laser irradiation

Zhang H., Wang C., Huang H., Yan J., Zhang L., Jiang M., Zhang Z.

Tribology International 200 2024年12月

ISSN 0301679X

Introducing wear-resistant layers or constructing microtextures is normally employed to improve the wear resistance of materials. However, single role of the wear-resistant layer or microtexture still could not effectively address the wear issue of titanium alloys. In this study, a sinusoidal nitriding layer is directly fabricated on the Ti6Al4V surface by one-step laser irradiation. Chemical composition and microstructure analysis indicate that the nitriding layer contains TiN and α-Ti phases, and it is metallurgically bonded to the heat-affected zone. Friction wear tests show a 96.9 % reduction in wear rate with dry sliding and 99.6 % with oil lubrication, without exhibiting groove orientation dependence. The wear mechanism is discussed by scrutinizing the morphology of the wear scars and their corresponding cross-sections.

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Abnormal wetting behavior transformation in RB-SiC composite induced by laser irradiation and annealing treatment

An H., Qian Y., Zhang Z., Huang H., Yan J.

Chemical Engineering Journal 499 2024年11月

ISSN 13858947

Multifunctional reaction-bonded silicon carbide (RB-SiC) surfaces with tailored wetting behaviors have garnered notable interest due to their potential applications across various fields. However, the inherent hard-brittle nature of RB-SiC ceramics poses substantial challenges for the facile and controllable preparation of homogeneous and heterogeneous wetting surfaces via conventional techniques. Herein, taking advantage of the fact that laser irradiation of RB-SiC can induce the formation of SiO2 phase and that SiO2 with high surface energy can inhibit the adsorption of organic matter, the surface wetting characteristics of RB-SiC ceramics are flexibly tuned through a hybrid processing technique combining laser irradiation and annealing treatment. The SiO2 content of the laser-irradiated surface can be regulated by varying the laser processing parameters. In the subsequent annealing process, the laser-irradiated surface with low SiO2 content achieves a wettability transition from superhydrophilicity to superhydrophobicity, whereas the laser-irradiated surface with high SiO2 content remains superhydrophilic. Inspired by annealing-induced significant difference in wettability, gradient wetting and extreme wettability contrast surfaces are prepared, enabling the directional transport of droplets. The homogeneous superhydrophobic surfaces produced at different annealing temperatures exhibit distinct anti-icing capabilities and adhesion properties. Importantly, the prepared superhydrophobic surfaces with varying adhesion forces can achieve no-loss droplet transport. This study provides a straightforward, high-efficient, and low-cost method for fabricating RB-SiC surfaces with diverse wetting behaviors, thereby promising to expand their utility spectrum and practical applicability.

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A cross-scale material removal prediction model for magnetorheological shear thickening polishing

Tian Y., Ma Z., Ma X., Li L., Yan J.

Journal of Materials Processing Technology 332 2024年11月

ISSN 09240136

Conventional polishing methods face significant challenges for achieving excellent performance on complex surfaces. The magnetorheological shear thickening polishing (MRSTP) method, with its dual-stimulus response of shear thickening and magnetization enhancement, offers an effective solution for polishing complex surfaces. However, existing models fail to elucidate the cross-scale material removal mechanisms in MRSTP owing to the coupling of magnetic and flow fields. In this study, a comprehensive model was proposed to address the the challenge of predicting the cross-scale material removal rate (MRR) in MRSTP for complex surfaces. Analytical and finite difference methods were employed to solve the pressure distribution during the MRSTP process using magnetohydrodynamics. By incorporating the pressure distribution, an MRR predictive model was developed for arbitrary points on the workpiece surface based on the indentation theory for active abrasive grains. The material removal mechanism was explored by considering elastic and plastic deformation under fluid pressure. The experimental validation showed a relative error of 14.9 % between the theoretical and experimental MRR. Experiments on aero-engine blade tenons demonstrated that the established MRR model is well suited for application to complex surfaces. This study ultimately reveals the material removal mechanism of MRSTP with coupled magnetic and flow field, providing a new foundation for predicting MRR on complex surfaces.

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Bridging Data Gaps: A Federated Learning Approach to Heat Emission Prediction in Laser Powder Bed Fusion

Lei R., Guo Y.B., Yan J., Guo W.G.

Journal of Manufacturing Science and Engineering 146 （ 10 ） 2024年10月

ISSN 10871357

Deep learning has impacted defect prediction in additive manufacturing (AM), which is important to ensure process stability and part quality. However, its success depends on extensive training, requiring large, homogeneous datasets - remaining a challenge for the AM industry, particularly for small- and medium-sized enterprises (SMEs). The unique and varied characteristics of AM parts, along with the limited resources of SMEs, hamper data collection, posing difficulties in the independent training of deep learning models. Addressing these concerns requires enabling knowledge sharing from the similarities in the physics of the AM process and defect formation mechanisms while carefully handling privacy concerns. Federated learning (FL) offers a solution to allow collaborative model training across multiple entities without sharing local data. This article introduces an FL framework to predict section-wise heat emission during laser powder bed fusion (LPBF), a vital process signature. It incorporates a customized long short-term memory (LSTM) model for each client, capturing the dynamic AM process's time-series properties without sharing sensitive information. Three advanced FL algorithms are integrated - federated averaging (FedAvg), FedProx, and FedAvgM - to aggregate model weights rather than raw datasets. Experiments demonstrate that the FL framework ensures convergence and maintains prediction performance comparable to individually trained models. This work demonstrates the potential of FL-enabled AM modeling and prediction where SMEs can improve their product quality without compromising data privacy.

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