4.6 Article

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

Journal

MATERIALS
Volume 15, Issue 16, Pages -

Publisher

MDPI
DOI: 10.3390/ma15165662

Keywords

convolution neural network; metal additive manufacturing; powder-spreading defect; selective laser melting

Funding

  1. National Science and Technology Council (NSTC), Taiwan [MOST 109-2221-E-006-087-MY3, MOST 110-2218-E-006-028, 111-2218-E-006-013]

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Metal laser melting manufacturing (MAM) has been widely used in various industries due to its high customization and rapid production, but defects during the manufacturing process are a common issue. This study developed a defect detection method based on convolutional neural networks to effectively identify and locate defects in the powder bed fusion equipment process.
Due to its advantages of high customization and rapid production, metal laser melting manufacturing (MAM) has been widely applied in the medical industry, manufacturing, aerospace and boutique industries in recent years. However, defects during the selective laser melting (SLM) manufacturing process can result from thermal stress or hardware failure during the selective laser melting (SLM) manufacturing process. To improve the product's quality, the use of defect detection during manufacturing is necessary. This study uses the process images recorded by powder bed fusion equipment to develop a detection method, which is based on the convolutional neural network. This uses three powder-spreading defect types: powder uneven, powder uncovered and recoater scratches. This study uses a two-stage convolutional neural network (CNN) model to finish the detection and segmentation of defects. The first stage uses the EfficientNet B7 to classify the images with/without defects, and then to locate the defects by evaluating three different instance segmentation networks in second stage. Experimental results show that the accuracy and Dice measurement of Mask-R-CNN network with ResNet 152 backbone can reach 0.9272 and 0.9438. The computational time of an image only takes approximately 0.2197 sec. The used CNN model meets the requirements of the early detected defects, regarding the SLM manufacturing process.

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