journal article·2022-09

Image Segmentation for Defect Analysis in Laser Powder Bed Fusion: Deep Data Mining of X-Ray Photography from Recent Literature

Jiahui Zhang, Tianyi Lyu, Yujie Hua, Zeren Shen, Qiang Sun, Yiming Rong, Yu Zou

Publisher page

Abstract

The in situ X-ray imaging method has attracted significant attention in the metal additive manufacturing community for characterizing keyhole dynamics and defect generation during laser-material interaction processes, particularly for laser powder bed fusion. Due to a high temporal and spatial resolution in this method, a vast volume of data are generated and collected, leading to a challenge for data processing and analysis. In this study, we present an accurate, robust, and powerful image analytical approach that can identify the high-fidelity automated features and extract important information from X-ray images. In total, we train six semantic segmentation models and six object detection models using 628 X-ray images obtained from two recent literature. Our study demonstrates that the U net + MobileNet model is the overall best choice among 12 models to recognize and extract desired regions, in terms of accuracy, time consumption, and dataset sensitivity. Using this model, we have collected and summarized geometric features and dynamic behaviors of the keyholes and generated bubbles. The image segmentation approach may pave the path for unveiling new mechanisms that might not be easily identified using conventional analysis methods in additive manufacturing processes.
Source: expertdata · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Additive Manufacturing Materials and Processes · Advanced X-ray and CT Imaging · Laser Material Processing Techniques

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (41)

Show source-provided references
1. Kandukuri S, Ze C (2021) Progress of metal AM and certification pathway. Trans Indian Natl Acad Eng 6(4):909–915. https://doi.org/10.1007/s41403-021-00242-x10.1007/s41403-021-00242-x ↗
2. Zhang Y et al (2018) Additive manufacturing of metallic materials: a review. J Mater Eng Perform 27(1):1–13. https://doi.org/10.1016/j.pmatsci.2017.10.00110.1016/j.pmatsci.2017.10.001 ↗
3. Yap CY et al (2015) Review of selective laser melting: materials and applications. Appl Phys Rev 2(4):041101. https://doi.org/10.1063/1.493592610.1063/1.4935926 ↗
4. Khairallah SA et al (2016) Laser powder-bed fusion additive manufacturing: physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones. Acta Mater 108:36–45. https://doi.org/10.1016/j.actamat.2016.02.01410.1016/j.actamat.2016.02.014 ↗
5. Gu D et al (2021) Material-structure-performance integrated laser-metal additive manufacturing. Science 372(6545):eabg1487. https://doi.org/10.1126/science.abg148710.1126/science.abg1487 ↗
6. King WE et al (2014) Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing. J Mater Process Technol 214(12):2915–2925. https://doi.org/10.1016/j.jmatprotec.2014.06.00510.1016/j.jmatprotec.2014.06.005 ↗
7. Hojjatzadeh SMH et al (2020) Direct observation of pore formation mechanisms during LPBF additive manufacturing process and high energy density laser welding. Int J Mach Tools Manuf 153:103555. https://doi.org/10.1016/j.ijmachtools.2020.10355510.1016/j.ijmachtools.2020.103555 ↗
8. Leuders S et al (2013) On the mechanical behaviour of titanium alloy TiAl6V4 manufactured by selective laser melting: fatigue resistance and crack growth performance. Int J Fatigue 48:300–307. https://doi.org/10.1016/j.ijfatigue.2012.11.01110.1016/j.ijfatigue.2012.11.011 ↗
9. Hojjatzadeh SMH et al (2019) Pore elimination mechanisms during 3D printing of metals. Nature Commun 10(1):1–8. https://doi.org/10.1038/s41467-019-10973-910.1038/s41467-019-10973-9 ↗
10. Sun TJJ (2020) Probing ultrafast dynamics in laser powder bed fusion using high-speed X-ray imaging: a review of research at the advanced photon source. JOM 72(3):999–1008. https://doi.org/10.1007/s11837-020-04015-910.1007/s11837-020-04015-9 ↗
11. Pyeon J et al (2021) Time-resolved geometric feature tracking elucidates laser-induced keyhole dynamics. Integr Mater Manuf Innov 10(4):677–688. https://doi.org/10.1007/s40192-021-00241-410.1007/s40192-021-00241-4 ↗
12. Huang Y et al (2022) Keyhole fluctuation and pore formation mechanisms during laser powder bed fusion additive manufacturing. Nature Commun 13(1):1170. https://doi.org/10.1007/s40192-021-00241-410.1007/s40192-021-00241-4 ↗
13. Zhao C et al (2020) Critical instability at moving keyhole tip generates porosity in laser melting. Science 370(6520):1080–1086. https://doi.org/10.1126/science.abd158710.1126/science.abd1587 ↗
14. Abràmoff MD, Magalhães PJ, Ram SJ (2004) Image processing with ImageJ. Biophotonics Int 11(7):36–42
15. Garcia-Garcia A, et al (2017) A review on deep learning techniques applied to semantic segmentation. https://arxiv.org/abs/1704.06857
16. Long J, Shelhamer E, Darrell T (2015) Fully convolutional networks for semantic segmentation. CVPR2015. https://doi.org/10.48550/arXiv.1411.403810.48550/arXiv.1411.4038 ↗
17. Ronneberger O, Fischer P, Brox T (2015) U-net: convolutional networks for biomedical image segmentation. In: International conference on medical image computing and computer-assisted intervention, Springer, Cham, pp 234–241. https://doi.org/10.48550/arXiv.1505.0459710.48550/arXiv.1505.04597 ↗
18. Badrinarayanan V, Kendall A, Cipolla R (2017) Segnet: A deep convolutional encoder-decoder architecture for image segmentation. IEEE Trans Pattern Anal Mach Intell 39(12):2481–2495. https://doi.org/10.1109/tpami.2016.264461510.1109/tpami.2016.2644615 ↗
19. Chen L-C et al (2017) Deeplab: Semantic image segmentation with deep convolutional nets, atrous convolution, and fully connected CRFs. IEEE Trans Pattern Anal Mach Intell 40(4):834–848. https://doi.org/10.1109/TPAMI.2017.269918410.1109/TPAMI.2017.2699184 ↗
20. Liu W, Rabinovich A, Berg AC (2015) Parsenet: Looking wider to see better. https://arxiv.org/abs/1506.04579
21. Visin F, et al (2016) Reseg: a recurrent neural network-based model for semantic segmentation. In: Proceedings of the IEEE conference on computer vision and pattern recognition workshops. https://doi.org/10.48550/arXiv.1511.0705310.48550/arXiv.1511.07053 ↗
22. Howard AG, et al (2017) Mobilenets: Efficient convolutional neural networks for mobile vision applications. https://arxiv.org/abs/1704.04861
23. He K, et al (2016) Deep residual learning for image recognition. In: Proceedings of the IEEE conference on computer vision and pattern recognition. https://doi.org/10.1109/CVPR.2016.9010.1109/CVPR.2016.90 ↗
24. Ronneberger O, Fischer P, Brox T (2015) U-Net: Convolutional networks for biomedical image segmentation. In: International conference on Medical image computing and computer-assisted intervention. Springer, Cham. https://doi.org/10.1007/978-3-319-24574-4_2810.1007/978-3-319-24574-4_28 ↗
25. Dasiopoulou S et al (2005) Knowledge-assisted semantic video object detection. IEEE Trans Circuits Syst Video Technol 15(10):1210–1224. https://doi.org/10.1109/TCSVT.2005.85423810.1109/TCSVT.2005.854238 ↗
26. Zhao Z-Q et al (2019) Object detection with deep learning: a review. IEEE Trans Neural Netw Learn Syst 30(11):3212–3232. https://doi.org/10.1109/tnnls.2018.287686510.1109/tnnls.2018.2876865 ↗
27. Zhiqiang W, Jun L (2017) A review of object detection based on convolutional neural network. In: 2017 36th Chinese Control Conference (CCC). IEEE. https://doi.org/10.23919/ChiCC.2017.802913010.23919/ChiCC.2017.8029130 ↗
28. Girshick R, et al (2014) Rich feature hierarchies for accurate object detection and semantic segmentation. In: Proceedings of the IEEE conference on computer vision and pattern recognition. https://doi.org/10.48550/arXiv.1311.252410.48550/arXiv.1311.2524 ↗
29. He K et al (2015) Spatial pyramid pooling in deep convolutional networks for visual recognition. IEEE Trans Pattern Anal Mach Intell 37(9):1904–1916. https://doi.org/10.1109/tpami.2015.238982410.1109/tpami.2015.2389824 ↗
30. Girshick R (2015) Fast R-CNN. In: Proceedings of the IEEE international conference on computer vision. https://doi.org/10.48550/arXiv.1504.0808310.48550/arXiv.1504.08083 ↗
31. Ren S et al (2015) Faster R-CNN: towards real-time object detection with region proposal networks. Adv Neural Inf Process Syst 28:91–99. https://doi.org/10.48550/arXiv.1506.0149710.48550/arXiv.1506.01497 ↗
32. Redmon J, et al (2016) You only look once: unified, real-time object detection. In: Proceedings of the IEEE conference on computer vision and pattern recognition. https://doi.org/10.1109/cvpr.2016.9110.1109/cvpr.2016.91 ↗
33. Liu W, et al (2016) SSD: Single shot multibox detector. In: European conference on computer vision. Springer, Cham. https://doi.org/10.1007/978-3-319-46448-0_210.1007/978-3-319-46448-0_2 ↗
34. Redmon J, Farhadi A (2018) Yolov3: An incremental improvement. arXiv preprint https://arXiv.org/:1804.02767
35. Bochkovskiy A, Wang C-Y, Liao H-YMJAPA (2020) Yolov4: Optimal speed and accuracy of object detection. https://arxiv.org/abs/2004.10934
36. Tan M, Le Q (2019) Efficientnet: rethinking model scaling for convolutional neural networks. In: International conference on machine learning, PMLR. https://doi.org/10.48550/arXiv.1905.1194610.48550/arXiv.1905.11946 ↗
37. Tan M, Pang R, Le QV (2020) Efficientdet: Scalable and efficient object detection. In: Proceedings of the IEEE/CVF conference on computer vision and pattern recognition. https://doi.org/10.1109/cvpr42600.2020.0107910.1109/cvpr42600.2020.01079 ↗
38. Welch G, Bishop G (1995) An introduction to the Kalman filter. https://arxiv.org/abs/1506.04579v2
39. Cunningham R et al (2019) Keyhole threshold and morphology in laser melting revealed by ultrahigh-speed X-ray imaging. Science 363(6429):849–852. https://doi.org/10.1126/science.aav468710.1126/science.aav4687 ↗
40. Gan Z et al (2021) Universal scaling laws of keyhole stability and porosity in 3D printing of metals. Nature Commun 12(1):1–8. https://doi.org/10.1038/s41467-021-22704-010.1038/s41467-021-22704-0 ↗
41. Huang Y, et al (2021) Keyhole fluctuation and pore formation mechanisms during laser powder bed fusion additive manufacturing. https://arxiv.org/abs/1506.04579v210.21203/rs.3.rs-683646/v1 ↗