MOSAIC: Mobile Object Segmentation under Adverse Imaging Conditions for Rapid L-PBF Keyhole Behavior Characterization

In laser powder bed fusion (L-PBF) processes, the rapid evolution of gas and fluid interactions complicates our ability to properly monitor or control the process, with unstable keyholes leading to porosity and spatter formation. High-speed operando x-ray imaging of the keyhole has been used to better understand the impact of these interactions on the monitoring and control of the L-PBF process. MOSAIC, a Mobile Object Segmentation algorithm for experiments under Adverse Imaging Conditions, is designed to perform rapid analysis of keyhole dynamics during active beamline experimentation without needing time consuming manual labeling or model training. Validation studies performed on 12 unique samples proved the robustness of MOSAIC with an average F1 score of 0.894 and a precision of 0.953 when compared to manually segmented images, performing equally or better than the SAM and YOLO machine learning methods tested. MOSAIC is efficient, processing frames cropped to a moving window approximately 150x250 pixels at 19.9 milliseconds per image on CPU, compared to 54 and 5284 milliseconds per image for inference on CPU for YOLO and SAM models.