Zhenyu James Kong | Searcharxiv

arXiv2026

Temperature-Dependent Multiphysics Modeling of Additive Friction Stir Deposition Using Multi-Task Coupled Physics-Informed Neural Networks

Additive friction stir deposition (AFSD) involves coupled thermal and material-flow fields governed by frictional heating, plastic deformation, and tool-imposed boundary conditions. High-fidelity finite-volume methods (FVMs) can resolve these fields but are computationally expensive, while constant-property approximations can distort the predicted thermo-mechanical response. This work develops a steady-state multi-task coupled physics-informed neural network (MCoPINN) to predict three-dimensional temperature and material-flow fields while reconstructing temperature-dependent thermal conductivity, density, and specific heat from sparse property measurements. A theoretical analysis decomposes prediction error into property reconstruction and neural field-solver contributions and characterizes the discrepancy associated with constant-property models. A controlled one-dimensional nonlinear-conduction study evaluates property reconstruction under sparse measurements. The framework is then evaluated for AFSD against a temperature-dependent FVM benchmark and experimental thermocouple measurements. MCoPINN reproduces the reference thermal and material-flow fields and reduces average temperature root-mean-square error from 50.13 K for the constant-property CoPINN to 30.28 K across four traverse speeds. MCoPINN requires approximately 8.5 hours of training per condition, compared with 52 hours for the FVM benchmark. These results demonstrate computationally efficient, physics-coupled prediction with temperature-dependent material properties.

cs.CE↗

arXiv2024

Advancing Additive Manufacturing through Deep Learning: A Comprehensive Review of Current Progress and Future Challenges

This paper presents the first comprehensive literature review of deep learning (DL) applications in additive manufacturing (AM). It addresses the need for a thorough analysis in this rapidly growing yet scattered field, aiming to bring together existing knowledge and encourage further development. Our research questions cover three major areas of AM: (i) design for AM, (ii) AM modeling, and (iii) monitoring and control in AM. We use a step-by-step approach following the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) guidelines to select papers from Scopus and Web of Science databases, aligning with our research questions. We include only those papers that implement DL across seven major AM categories - binder jetting, directed energy deposition, material extrusion, material jetting, powder bed fusion, sheet lamination, and vat photopolymerization. Our analysis reveals a trend towards using deep generative models, such as generative adversarial networks, for generative design in AM. It also highlights an increasing effort to incorporate process physics into DL models to improve AM process modeling and reduce data requirements. Additionally, there is growing interest in using 3D point cloud data for AM process monitoring, alongside traditional 1D and 2D formats. Finally, this paper summarizes the current challenges and recommends some of the promising opportunities in this domain for further investigation with a special focus on (i) generalizing DL models for a wide range of geometry types, (ii) managing uncertainties both in AM data and DL models, (iii) overcoming limited, imbalanced, and noisy AM data issues by incorporating deep generative models, and (iv) unveiling the potential of interpretable DL for AM.

cs.LG↗