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Advanced predictive quality assessment for ultrasonic additive manufacturing with deep learning model

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Abstract

Ultrasonic Additive Manufacturing (UAM) employs ultrasonic welding to bond similar or dissimilar metal foils to a substrate, resulting in solid, consolidated metal components. However, certain processing conditions can lead to inter-layer defects, affecting the final product’s quality. This study develops a method to monitor in-process quality using deep learning-based convolutional neural networks (CNNs). We evaluated the CNN on their ability to classify samples with and without embedded thermocouples across five power levels (300 W, 600 W, 900 W, 1200 W, 1500 W) using thermal images with supervised labeling. Four distinct CNN classification models were created for different scenarios including without (baseline) and with thermocouples, only without thermocouples across power levels, only with thermocouples across power levels, and combined without and with thermocouples across power levels. The models achieved 99.14% accuracy on combined baseline and thermocouple images, 98.55% for baseline images across power levels, 96.70% for thermocouple images, and 98.36% for both types across power levels. The high accuracy, above 96.00%, demonstrates the system’s effectiveness in identifying and classifying conditions within the UAM process, providing a reliable machine learning tool for quality assurance and process control in manufacturing environments.

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Acknowledgements

This material is based upon work supported by the Air Force Research Laboratory, AFWERX, AFRL/RGKB under Contract No. FA864923P1242. Any opinions, findings and conclusions or recommendations expressed in this material are those of the authors and do not necessarily reflect the views of the Air Force Research Laboratory, AFWERX, AFRL/RGKB. The manuscript was cleared for public release on 10/04/2024, with Case Number: AFRL-2024-5576. The authors would also like to acknowledge Mark Norfolk, Jason A. Riley, and Matthew Burkhart of Fabrisonic LLC.

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Authors and Affiliations

  1. Polaron Analytics, 9059 Springboro Pike, Miamisburg, OH, 45342, USA

    Lokendra Poudel, Duy-Nhat Phan & Rahul Bhowmik

  2. University of Dayton Research Institute, 300 College Park, Dayton, OH, 45469, USA

    Sushant Jha & Ryan Meeker

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  1. Lokendra Poudel
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  2. Sushant Jha
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Correspondence to Lokendra Poudel or Rahul Bhowmik.

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Poudel, L., Jha, S., Meeker, R. et al. Advanced predictive quality assessment for ultrasonic additive manufacturing with deep learning model. J Intell Manuf (2025). https://doi.org/10.1007/s10845-025-02582-9

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  • DOI: https://doi.org/10.1007/s10845-025-02582-9

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