In-situ surface porosity prediction in DED printed SS316L parts using multimodal sensor fusion

This study aims to relate the time-frequency patterns of acoustic emission (AE) and other multi-modal sensor data collected in a hybrid directed energy deposition (DED) process to the pore formations at high spatial (0.5 mm) and time (< 1ms) resolutions. Adapting an explainable AI method in LIME (Local Interpretable Model-Agnostic Explanations), certain high-frequency waveform signatures of AE are to be attributed to two major pathways for pore formation in a DED process, namely, spatter events and insufficient fusion between adjacent printing tracks from low heat input. This approach opens an exciting possibility to predict, in real-time, the presence of a pore in every voxel (0.5 mm in size) as they are printed, a major leap forward compared to prior efforts. Synchronized multimodal sensor data including force, AE, vibration and temperature were gathered while an SS316L material sample was printed and subsequently machined. A deep convolution neural network classifier was used to identify the presence of pores on a voxel surface based on time-frequency patterns (spectrograms) of the sensor data collected during the process chain. The results suggest signals collected during DED were more sensitive compared to those from machining for detecting porosity in voxels (classification test accuracy of 87%). The underlying explanations drawn from LIME analysis suggests that energy captured in high frequency AE waveforms are 33% lower for porous voxels indicating a relatively lower laser-material interaction in the melt pool, and hence insufficient fusion and poor overlap between adjacent printing tracks. The porous voxels for which spatter events were prevalent during printing had about 27% higher energy contents in the high frequency AE band compared to other porous voxels. These signatures from AE signal can further the understanding of pore formation from spatter and insufficient fusion.