Statistical Parameterized Physics-Based Machine Learning Digital Twin Models for Laser Powder Bed Fusion Process

A digital twin (DT) is a virtual representation of physical process, products and/or systems that requires a high-fidelity computational model for continuous update through the integration of sensor data and user input. In the context of laser powder bed fusion (LPBF) additive manufacturing, a digital twin of the manufacturing process can offer predictions for the produced parts, diagnostics for manufacturing defects, as well as control capabilities. This paper introduces a parameterized physics-based digital twin (PPB-DT) for the statistical predictions of LPBF metal additive manufacturing process. We accomplish this by creating a high-fidelity computational model that accurately represents the melt pool phenomena and subsequently calibrating and validating it through controlled experiments. In PPB-DT, a mechanistic reduced-order method-driven stochastic calibration process is introduced, which enables the statistical predictions of the melt pool geometries and the identification of defects such as lack-of-fusion porosity and surface roughness, specifically for diagnostic applications. Leveraging data derived from this physics-based model and experiments, we have trained a machine learning-based digital twin (PPB-ML-DT) model for predicting, monitoring, and controlling melt pool geometries. These proposed digital twin models can be employed for predictions, control, optimization, and quality assurance within the LPBF process, ultimately expediting product development and certification in LPBF-based metal additive manufacturing.

Emergence of Shape Bias in Convolutional Neural Networks through Activation Sparsity

Current deep-learning models for object recognition are known to be heavily biased toward texture. In contrast, human visual systems are known to be biased toward shape and structure. What could be the design principles in human visual systems that led to this difference? How could we introduce more shape bias into the deep learning models? In this paper, we report that sparse coding, a ubiquitous principle in the brain, can in itself introduce shape bias into the network. We found that enforcing the sparse coding constraint using a non-differential Top-K operation can lead to the emergence of structural encoding in neurons in convolutional neural networks, resulting in a smooth decomposition of objects into parts and subparts and endowing the networks with shape bias. We demonstrated this emergence of shape bias and its functional benefits for different network structures with various datasets. For object recognition convolutional neural networks, the shape bias leads to greater robustness against style and pattern change distraction. For the image synthesis generative adversary networks, the emerged shape bias leads to more coherent and decomposable structures in the synthesized images. Ablation studies suggest that sparse codes tend to encode structures, whereas the more distributed codes tend to favor texture. Our code is host at the github repository: \url{https://github.com/Crazy-Jack/nips2023_shape_vs_texture}

A Hierarchical Deep Convolutional Neural Network and Gated Recurrent Unit Framework for Structural Damage Detection

Structural damage detection has become an interdisciplinary area of interest for various engineering fields, while the available damage detection methods are being in the process of adapting machine learning concepts. Most machine learning based methods heavily depend on extracted ``hand-crafted" features that are manually selected in advance by domain experts and then, fixed. Recently, deep learning has demonstrated remarkable performance on traditional challenging tasks, such as image classification, object detection, etc., due to the powerful feature learning capabilities. This breakthrough has inspired researchers to explore deep learning techniques for structural damage detection problems. However, existing methods have considered either spatial relation (e.g., using convolutional neural network (CNN)) or temporal relation (e.g., using long short term memory network (LSTM)) only. In this work, we propose a novel Hierarchical CNN and Gated recurrent unit (GRU) framework to model both spatial and temporal relations, termed as HCG, for structural damage detection. Specifically, CNN is utilized to model the spatial relations and the short-term temporal dependencies among sensors, while the output features of CNN are fed into the GRU to learn the long-term temporal dependencies jointly. Extensive experiments on IASC-ASCE structural health monitoring benchmark and scale model of three-span continuous rigid frame bridge structure datasets have shown that our proposed HCG outperforms other existing methods for structural damage detection significantly.