Utilising unsupervised machine learning and IoT for cost-effective anomaly detection in multi-layer wire arc additive manufacturing

Mattera, Giulio; Yap, Emily W.; Polden, Joseph; Brown, Evan; Nele, Luigi; Van Duin, Stephen

doi:10.1007/s00170-024-14648-8

Int J Adv Manuf Technol

2024

DOI: 10.1007/s00170-024-14648-8

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Utilising unsupervised machine learning and IoT for cost-effective anomaly detection in multi-layer wire arc additive manufacturing

Giulio Mattera,

Emily W. Yap,

Joseph Polden

et al.

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Explaining the Anomaly Detection in Additive Manufacturing via Boosting Models and Frequency Analysis

Vozza,

Polden,

Mattera

et al. 2024

Mathematics

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Anomaly detection is an important feature in modern additive manufacturing (AM) systems to ensure quality of the produced components. Although this topic is well discussed in the literature, current methods rely on black-box approaches, limiting our understanding of why anomalies occur, making complex the root cause identification and the consequent decision support about the action to take to mitigate them. This work addresses these limitations by proposing a structured workflow designed to enhance the explainability of anomaly detection models. Using the wire arc additive manufacturing (WAAM) process as a case study, we examined 14 wall structures printed with INVAR36 alloy under varying process parameters, producing both defect-free and defective parts. These parts were classified based on surface appearance and welding camera images. We collected welding current and voltage data at a 5 kHz sampling rate and extracted features from both time and frequency domains using a knowledge-based approach. Isolation Forest, k-Nearest Neighbor, Artificial Neural Network, XGBoost, and LGBM models were trained on these features, and the results shown best performance of boosting models, achieving F1 scores of 0.927 and 0.945, respectively. These models presented higher performance compared to other models like k-Nearest Neighbor, whereas Isolation Forest and Artificial Neural Network posses lower performance due to overfitting, with an F1 score of 0.507 and 0.56, respectively. Then, by leveraging the feature importance capabilities of these models, we identified key signal characteristics that distinguish between normal and anomalous behavior, improving the explainability of the detection process and in general about the process physics.

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Explaining the Anomaly Detection in Additive Manufacturing via Boosting Models and Frequency Analysis

Vozza,

Polden,

Mattera

et al. 2024

Mathematics

View full text Add to dashboard Cite

show abstract

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Utilising unsupervised machine learning and IoT for cost-effective anomaly detection in multi-layer wire arc additive manufacturing

Cited by 1 publication

References 51 publications

Explaining the Anomaly Detection in Additive Manufacturing via Boosting Models and Frequency Analysis

Explaining the Anomaly Detection in Additive Manufacturing via Boosting Models and Frequency Analysis

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