Towards a Digital Twin Framework in Additive Manufacturing: Machine
  Learning and Bayesian Optimization for Time Series Process Optimization
Vispi Karkaria Anthony Goeckner Rujing Zha Jie Chen Jianjing Zhang Qi Zhu Jian Cao Robert X. Gao Wei Chen
Laser-directed-energy deposition (DED) offers advantages in additive
manufacturing (AM) for creating intricate geometries and material grading. Yet,
challenges like material inconsistency and part variability remain, mainly due
to its layer-wise fabrication. A key issue is heat accumulation during DED,
which affects the material microstructure and properties. While closed-loop
control methods for heat management are common in DED research, few integrate
real-time monitoring, physics-based modeling, and control in a unified
framework. Our work presents a digital twin (DT) framework for real-time
predictive control of DED process parameters to meet specific design
objectives. We develop a surrogate model using Long Short-Term Memory
(LSTM)-based machine learning with Bayesian Inference to predict temperatures
in DED parts. This model predicts future temperature states in real time. We
also introduce Bayesian Optimization (BO) for Time Series Process Optimization
(BOTSPO), based on traditional BO but featuring a unique time series process
profile generator with reduced dimensions. BOTSPO dynamically optimizes
processes, identifying optimal laser power profiles to attain desired
mechanical properties. The established process trajectory guides online
optimizations, aiming to enhance performance. This paper outlines the digital
twin framework's components, promoting its integration into a comprehensive
system for AM.