TDIP: Tunable Deep Image Processing, a Real Time Melt Pool Monitoring Solution

TL;DR

This paper introduces TDIP, a tunable deep image processing method that enables real-time melt pool monitoring in metal additive manufacturing, significantly improving processing speed and accuracy over traditional techniques.

Contribution

The paper presents a novel tunable deep image processing model that replicates and enhances conventional image analysis for real-time melt pool monitoring in additive manufacturing.

Findings

Achieved over 94% estimation accuracy.

Processed 500 images per second, vastly faster than traditional methods.

Enabled real-time process and quality estimation in metal AM.

Abstract

In the era of Industry 4.0, Additive Manufacturing (AM), particularly metal AM, has emerged as a significant contributor due to its innovative and cost-effective approach to fabricate highly intricate geometries. Despite its potential, this industry still lacks real-time capable process monitoring algorithms. Recent advancements in this field suggest that Melt Pool (MP) signatures during the fabrication process contain crucial information about process dynamics and quality. To obtain this information, various sensory approaches, such as high-speed cameras-based vision modules are employed for online fabrication monitoring. However, many conventional in-depth analyses still cannot process all the recorded data simultaneously. Although conventional Image Processing (ImP) solutions provide a targeted tunable approach, they pose a trade-off between convergence certainty and convergence speed. As a result, conventional methods are not suitable for a dynamically changing application like MP monitoring. Therefore, this article proposes the implementation of a Tunable Deep Image Processing (TDIP) method to address the data-rich monitoring needs in real-time. The proposed model is first trained to replicate an ImP algorithm with tunable features and methodology. The TDIP model is then further improved to account for MP geometries and fabrication quality based on the vision input and process parameters. The TDIP model achieved over 94% estimation accuracy with more than 96% R2 score for quality, geometry, and MP signature estimation and isolation. The TDIP model can process 500 images per second, while conventional methods taking a few minutes per image. This significant processing time reduction enables the integration of vision-based monitoring in real-time for processes and quality estimation.