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Related Experiment Video

Updated: Jan 7, 2026

Automatic Laser-based Geometry Capture for Finite Element Analysis of Weld Beads
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Machine Learning-Driven Multi-Objective Optimization of Bead Geometry and Energy Efficiency in Laser-Arc Hybrid

Chunyang Xia1,2, Kui Zeng3, Jiawei Ning3

  • 1College of Engineering, Ocean University of China, Qingdao 266100, China.

Materials (Basel, Switzerland)
|December 31, 2025
PubMed
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This summary is machine-generated.

This study introduces a machine learning framework for laser-arc hybrid additive manufacturing (LAHAM) to predict and optimize bead geometry and energy efficiency. The developed models effectively balance deposition accuracy with energy utilization for improved manufacturing processes.

Area of Science:

  • Materials Science and Engineering
  • Manufacturing Technology
  • Computational Science

Background:

  • Laser-arc hybrid additive manufacturing (LAHAM) presents challenges in predicting and controlling bead geometry and energy consumption due to complex nonlinear process interactions.
  • Accurate prediction and control are crucial for optimizing deposition accuracy and energy utilization in LAHAM.

Purpose of the Study:

  • To develop a machine learning (ML) framework for predicting bead width, height, and deposition volume per unit energy (DVUE) in LAHAM.
  • To optimize process parameters for enhanced deposition accuracy and energy efficiency.

Main Methods:

  • Experimental data was used to train and evaluate multiple regression models, including Support Vector Regression, Gaussian Process Regression (GPR), Neural Networks, and XGBoost.
Keywords:
additive manufacturingbead geometryenergy efficiencylaser–arc hybridmulti-objective optimization

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  • Gaussian Process Regression (GPR) was selected for its superior performance in capturing nonlinear relationships and further optimized using Bayesian Optimization and Particle Swarm Optimization.
  • Optimized GPR models were integrated with the NSGA-II multi-objective optimization algorithm.
  • Main Results:

    • The proposed ML framework successfully predicted bead geometry and DVUE in LAHAM.
    • Optimized GPR models achieved superior performance in capturing complex nonlinear process dynamics.
    • The NSGA-II algorithm identified Pareto-optimal process parameters, balancing geometric deviations and DVUE.

    Conclusions:

    • The developed ML framework provides a reliable and intelligent strategy for optimizing process parameters in hybrid additive manufacturing.
    • The approach effectively balances deposition accuracy and energy utilization rate.
    • This research contributes to advancing the control and efficiency of LAHAM processes.