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Deep Learning Applied to Defect Detection in Powder Spreading Process of Magnetic Material Additive Manufacturing.

Hsin-Yu Chen1, Ching-Chih Lin1, Ming-Huwi Horng2

  • 1Department of Mechanical Engineering, National Cheng Kung University, Tainan 701, Taiwan.

Materials (Basel, Switzerland)
|August 26, 2022
PubMed
Summary
This summary is machine-generated.

This study introduces a convolutional neural network (CNN) for detecting defects in metal additive manufacturing (MAM) using selective laser melting (SLM). The developed method accurately identifies powder-spreading defects, improving product quality.

Keywords:
convolution neural networkmetal additive manufacturingpowder-spreading defectselective laser melting

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Computer Vision

Background:

  • Metal additive manufacturing (MAM), particularly selective laser melting (SLM), offers high customization and rapid production for industries like medical, aerospace, and manufacturing.
  • Defects arising from thermal stress or hardware issues during SLM can compromise product quality, necessitating in-situ defect detection.
  • Powder-spreading defects, including uneven powder, uncovered areas, and recoater scratches, are common issues in SLM.

Purpose of the Study:

  • To develop an automated defect detection method for SLM processes using convolutional neural networks (CNNs).
  • To accurately identify and segment three types of powder-spreading defects: powder uneven, powder uncovered, and recoater scratches.
  • To evaluate the performance and computational efficiency of the proposed CNN model for real-time defect detection.

Main Methods:

  • Utilized process images captured by powder bed fusion equipment for defect detection.
  • Developed a two-stage CNN model: EfficientNet B7 for initial defect classification and instance segmentation networks for defect localization.
  • Evaluated Mask R-CNN with a ResNet 152 backbone for defect segmentation.

Main Results:

  • The Mask R-CNN model achieved high accuracy (0.9272) and Dice measurement (0.9438) in defect detection and segmentation.
  • The CNN model demonstrated efficient processing, with an approximate computational time of 0.2197 seconds per image.
  • The developed method effectively meets the requirements for early defect detection in SLM manufacturing.

Conclusions:

  • The proposed CNN-based approach provides an effective solution for automated defect detection in SLM.
  • The high accuracy and speed of the model contribute to improved quality control in metal additive manufacturing.
  • This method supports the reliable production of high-quality components in demanding industries.