Title: Monitoring and flaw detection during wire-based directed energy deposition using in-situ acoustic sensing and wavelet graph signal analysis

Abstract

The goal of this work is to detect flaw formation in the wire-based directed energy deposition (W-DED) process using in-situ sensor data. The W-DED studied in this work is analogous to metal inert gas electric arc welding. The adoption of W-DED in industry is limited because the process is susceptible to stochastic and environmental disturbances that cause instabilities in the electric arc, eventually leading to flaw formation, such as porosity and suboptimal geometric integrity. Moreover, due to the large size of W-DED parts, it is difficult to detect flaws post-process using non-destructive techniques, such as X-ray computed tomography. Accordingly, the objective of this work is to detect flaw formation in W-DED parts using data acquired from an acoustic (sound) sensor installed near the electric arc. To realize this objective, we develop and apply a novel wavelet integrated graph theory approach. The approach extracts a single feature called graph Laplacian Fiedler number from the noise-contaminated acoustic sensor data, which is subsequently tracked in a statistical control chart. Using this approach, the onset of various types of flaws are detected with a false alarm rate less-than 2%. This work demonstrates the potential of using advanced data analytics for in-situ monitoring of W-DED.

Authors:

Bevans, Benjamin ^[1]; Ramalho, André ^[2]; Smoqi, Ziyad ^[3]; Gaikwad, Aniruddha ^[3]; Santos, Telmo G. ^[2]; Rao, Prahalad ^[1]; Oliveira, J. P. ^[2]

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+ Show Author Affiliations

1. Univ. of Nebraska, Lincoln, NE (United States); Virginia Polytechnic Inst. and State Univ. (Virginia Tech), Blacksburg, VA (United States)
2. Universidade NOVA de Lisboa, Caparica (Portugal)
3. Univ. of Nebraska, Lincoln, NE (United States)

Publication Date:

Fri Dec 09 00:00:00 EST 2022

Research Org.:

Univ. of Nebraska, Lincoln, NE (United States)

Sponsoring Org.:

USDOE Office of Science (SC); National Science Foundation (NSF); Fundação para a Ciência e a Tecnologia (FCT)

OSTI Identifier:

1907967

Grant/Contract Number:  

SC0021136; CMMI-1719388; CMMI-1920245; CMMI-1739696; CMMI-1752069; PFI-TT 2044710; ECCS 2020246; ECCS-2025298; UI/BD/151018/2021; UID/00667/2020; LA/P/0037/2020; UIDP/50025/2020; UIDB/50025/2020

Resource Type:

Accepted Manuscript

Journal Name:

Materials & Design

Additional Journal Information:

Journal Volume: 225; Journal ID: ISSN 0264-1275

Publisher:

Elsevier

Country of Publication:

United States

Language:

English

Subject:

42 ENGINEERING; Wire-based directed energy deposition; Process flaw monitoring; Acoustic sensor; Wavelet filtering; Graph theory