Semi-supervised learning for real-time anomaly detection in pulsed transfer wire arc additive manufacturing

In Wire-Arc Additive Manufacturing (WAAM), ensuring the quality and integrity of components is of key importance and performing anomaly detection during production is an efficient strategy for preventing defects and maintaining an acceptable quality with lower costs compared to the development of complex supervised learning techniques. This paper presents an approach based on semi-supervised learning for real-time anomaly detection in the production of Inconel 718 components via the Pulsed Transfer WAAM process. The workflow is based on the use of training data obtained by employing established process parameters, similar to what is done in Welding Procedure Qualification Records (WPQRs), to develop a semi-supervised anomaly detection application. The proposed approach involves depositing material using the already established process parameters and collecting the corresponding welding data in terms of welding current and voltage sensor signals. The collected data are then employed to train an unsupervised algorithm by using solely good deposition data to learn hidden complex patterns of normality and hence detect anomalies based on deviations from these patterns. With this aim, global and local features are extracted from the welding current and voltage sensor signals in both time and time-frequency domains via Wavelet Transform technique and a deep learning approach based on a residual convolutional autoencoder. To showcase the effectiveness of the proposed approach, a case study involving wire arc additive manufacturing of Inconel 718 components was conducted. The proposed algorithm was tested and achieved an F-score of 0.895, representing a 30 % improvement over state-of-the-art methods that rely on time domain features for anomaly detection. This research work contributes to the improvement of anomaly detection methodologies, offering substantial advantages over alternative techniques for quality control and reliability of additive manufacturing processes such as WAAM.