A physical simulation-machine learning model for optimal process schemes in laser-based directed energy deposition process.

• A powder-scale high precision multi-physics model is developed to depict the DED-LB process. • The single-track Inconel 718 alloy DED-LB experiments are used to validate the powder scale model and GPR model results. • The physically based-data driven agent model is developed to rapidly and accurately predict the geometry and dilution rate. • The DED-LB PS-ML model for optimal process maps is developed to achieve process parameter optimization using a comparatively small accurate data. The major challenge faced is the definition of optimal process variables for rich quality of fabricated parts in laser-based directed energy deposition (DED-LB) processes. However, predicting the optimal process scheme using machine learning models is still challenging owing to the need for a large amount of training experimental data with high costs in DED-LB. In view of this, a physical simulation (PS)-machine learning (ML) model using a relatively small accurate data set of 31 simulation data for optimal process schemes is proposed in DED-LB process in this study. Firstly, a powder-scale high precision phenomenon model incorporating the mass transfer, phase transformations and heat transfer and using Lagrangian particle model to add mass is developed to depict the DED-LB process. Then, a Gaussian process regression (GPR) agent model is established to rapidly and accurately predict the geometry and dilution rate of deposition tracks under different manufacturing parameters based on the high precision simulation results. Finally, a PS-ML model for process parameter optimization is developed using the particle swarm algorithm (PSO), and the optimized parameters are experimentally validated. The results show that the developed powder-scale model and GPR model results are consistent with the Inconel 718 alloy experimental results. The proposed PS-ML model can increase the accuracy of the ML models even with a small simulation data set. None of PS-ML model optimization results has a relative error of more than 3% to the experimental results, and the dilution rate is reduced by up to 61.66% compared to the experimental design parameters without optimization. The proposed physical simulation-machine learning model in this study enables inexpensive and accurate optimization of DED-LB process parameters. [ABSTRACT FROM AUTHOR]