arXiv subjects

Y. B. Guo

Publications and source records attributed to Y. B. Guo.

7 recordsLinked to original sources

arXiv2026

Physics-Informed Machine Learning Regulated by Finite Element Analysis for Simulation Acceleration of Melt Pool Dynamics in Laser Powder Bed Fusion

Efficient simulation of Laser Powder Bed Fusion (LPBF) is crucial for process prediction due to the lasting issue of high computational cost associated with traditional numerical methods such as finite element analysis (FEA). While a Physics-Informed Neural Network (PINN) can predict solution fields with small training data and enables the generalization of new process parameters via transfer learning, it suffers from accuracy degradation in time-dependent problems due to the accumulation of residual and the difficulty in capturing the steep spatial and temporal gradients inherent in the LPBF process. To overcome this issue, this study develops an efficient modeling framework, FEA-Regulated Physics-Informed Neural Network (FEA-PINN), to accelerate the prediction of melt pool dynamics phenomena in an LPBF process while maintaining the FEA accuracy. The innovation of FEA-PINN manifested itself in two aspects. First, a novel strategy has been developed within the PINN model to capture the dynamic phase change of powder-liquid-solid, enabling the tracking of material status during laser melting. The model further incorporates temperature-dependent material properties, phase change behavior of the powder bed, Marangoni convection, and natural convection within the melt pool. Second, the FEA-PINN framework integrates corrective FEA simulations during inference to enforce physical consistency, reduce error drift, and capture the steep gradients. A comparative analysis shows that FEA-PINN achieves accuracy comparable to FEA while significantly reducing computational cost. The framework has been validated against benchmark FEA data for single-track scanning in LPBF.

cs.LG↗

arXiv2025

Real-Time AI-Driven Milling Digital Twin Towards Extreme Low-Latency

Digital twin (DT) enables smart manufacturing by leveraging real-time data, AI models, and intelligent control systems. This paper presents a state-of-the-art analysis on the emerging field of DTs in the context of milling. The critical aspects of DT are explored through the lens of virtual models of physical milling, data flow from physical milling to virtual model, and feedback from virtual model to physical milling. Live data streaming protocols and virtual modeling methods are highlighted. A case study showcases the transformative capability of a real-time machine learning-driven live DT of tool-work contact in a milling process. Future research directions are outlined to achieve the goals of Industry 4.0 and beyond.

eess.SY↗

arXiv2025

Integrated physics-informed learning and resonance process signature for the prediction of fatigue crack growth for laser-fused alloys

Fatigue behaviors of metal components by laser fusion suffer from scattering due to random geometrical defects (e.g., porosity, lack of fusion). Monitoring fatigue crack initiation and growth is critical, especially for laser-fused components with significant inherent fatigue scattering. Conventional statistics-based curve-fitting fatigue models have difficulty incorporating significant scattering in their fatigue life due to the random geometrical defects. A scattering-informed predictive method is needed for laser-fused materials' crack size and growth. Current data-driven machine learning could circumvent the issue of deterministic modeling, but results in a black-box function that lacks interpretability. To address these challenges, this study explores a novel nondimensionalized physics-informed machine learning (PIML) model to predict fatigue crack growth of laser-fused SS-316L by integrating fatigue laws and constraints with small data to ensure a realistic and interpretable prediction. Resonance process signature data were leveraged with Paris's law to train the PIML model without experimental crack growth data. The results show that Paris's law constants can be learned with good similarity to comparable data from the literature, and the crack growth rate can be predicted to compute crack sizes.

cs.CE↗

arXiv2025

Computational, Data-Driven, and Physics-Informed Machine Learning Approaches for Microstructure Modeling in Metal Additive Manufacturing

Metal additive manufacturing enables unprecedented design freedom and the production of customized, complex components. However, the rapid melting and solidification dynamics inherent to metal AM processes generate heterogeneous, non-equilibrium microstructures that significantly impact mechanical properties and subsequent functionality. Predicting microstructure and its evolution across spatial and temporal scales remains a central challenge for process optimization and defect mitigation. While conventional experimental techniques and physics-based simulations provide a physical foundation and valuable insights, they face critical limitations. In contrast, data-driven machine learning offers an alternative prediction approach and powerful pattern recognition but often operate as black-box, lacking generalizability and physical consistency. To overcome these limitations, physics-informed machine learning, including physics-informed neural networks, has emerged as a promising paradigm by embedding governing physical laws into neural network architectures, thereby enhancing accuracy, transparency, data efficiency, and extrapolation capabilities. This work presents a comprehensive evaluation of modeling strategies for microstructure prediction in metal AM. The strengths and limitations of experimental, computational, and data-driven methods are analyzed in depth, and highlight recent advances in hybrid PIML frameworks that integrate physical knowledge with ML. Key challenges, such as data scarcity, multi-scale coupling, and uncertainty quantification, are discussed alongside future directions. Ultimately, this assessment underscores the importance of PIML-based hybrid approaches in enabling predictive, scalable, and physically consistent microstructure modeling for site-specific, microstructure-aware process control and the reliable production of high-performance AM components.

cs.LG↗

arXiv2024

Thermal-Mechanical Physics Informed Deep Learning For Fast Prediction of Thermal Stress Evolution in Laser Metal Deposition

Understanding thermal stress evolution in metal additive manufacturing (AM) is crucial for producing high-quality components. Recent advancements in machine learning (ML) have shown great potential for modeling complex multiphysics problems in metal AM. While physics-based simulations face the challenge of high computational costs, conventional data-driven ML models require large, labeled training datasets to achieve accurate predictions. Unfortunately, generating large datasets for ML model training through time-consuming experiments or high-fidelity simulations is highly expensive in metal AM. To address these challenges, this study introduces a physics-informed neural network (PINN) framework that incorporates governing physical laws into deep neural networks (NNs) to predict temperature and thermal stress evolution during the laser metal deposition (LMD) process. The study also discusses the enhanced accuracy and efficiency of the PINN model when supplemented with small simulation data. Furthermore, it highlights the PINN transferability, enabling fast predictions with a set of new process parameters using a pre-trained PINN model as an online soft sensor, significantly reducing computation time compared to physics-based numerical models while maintaining accuracy.

cs.LG↗

arXiv2024

Physics-Informed Machine Learning for Smart Additive Manufacturing

Compared to physics-based computational manufacturing, data-driven models such as machine learning (ML) are alternative approaches to achieve smart manufacturing. However, the data-driven ML's "black box" nature has presented a challenge to interpreting its outcomes. On the other hand, governing physical laws are not effectively utilized to develop data-efficient ML algorithms. To leverage the advantages of ML and physical laws of advanced manufacturing, this paper focuses on the development of a physics-informed machine learning (PIML) model by integrating neural networks and physical laws to improve model accuracy, transparency, and generalization with case studies in laser metal deposition (LMD).

cs.LG↗

arXiv2023

Physics-Informed Machine Learning of Argon Gas-Driven Melt Pool Dynamics

Melt pool dynamics in metal additive manufacturing (AM) is critical to process stability, microstructure formation, and final properties of the printed materials. Physics-based simulation including computational fluid dynamics (CFD) is the dominant approach to predict melt pool dynamics. However, the physics-based simulation approaches suffer from the inherent issue of very high computational cost. This paper provides a physics-informed machine learning (PIML) method by integrating neural networks with the governing physical laws to predict the melt pool dynamics such as temperature, velocity, and pressure without using any training data on velocity. This approach avoids solving the highly non-linear Navier-Stokes equation numerically, which significantly reduces the computational cost. The difficult-to-determine model constants of the governing equations of the melt pool can also be inferred through data-driven discovery. In addition, the physics-informed neural network (PINN) architecture has been optimized for efficient model training. The data-efficient PINN model is attributed to the soft penalty by incorporating governing partial differential equations (PDEs), initial conditions, and boundary conditions in the PINN model.

cs.LG↗