Automated Porosity Characterization for Aluminum Die Casting Materials Using X-ray Radiography, Synthetic X-ray Data Augmentation by Simulation, and Machine Learning.

Detection and characterization of hidden defects, impurities, and damages in homogeneous materials like aluminum die casting materials, as well as composite materials like Fiber-Metal Laminates (FML), is still a challenge. This work discusses methods and challenges in data-driven modeling of automated damage and defect detectors using measured X-ray single- and multi-projection images. Three main issues are identified: Data and feature variance, data feature labeling (for supervised machine learning), and the missing ground truth. It will be shown that simulation of synthetic measuring data can deliver a ground truth dataset and accurate labeling for data-driven modeling, but it cannot be used directly to predict defects in manufacturing processes. Noise has a significant impact on the feature detection and will be discussed. Data-driven feature detectors are implemented with semantic pixel Convolutional Neural Networks. Experimental data are measured with different devices: A low-quality and low-cost (Low-Q) X-ray radiography, a typical industrial mid-quality X-ray radiography and Computed Tomography (CT) system, and a state-of-the-art high-quality µ-CT device. The goals of this work are the training of robust and generalized data-driven ML feature detectors with synthetic data only and the transition from CT to single-projection radiography imaging and analysis. Although, as the title implies, the primary task is pore characterization in aluminum high-pressure die-cast materials, but the methods and results are not limited to this use case.

Programmable Density of Laser Additive Manufactured Parts by Considering an Inverse Problem.

In this Article, the targeted adjustment of the relative density of laser additive manufactured components made of AlSi10Mg is considered. The interest in demand-oriented process parameters is steadily increasing. Thus, shorter process times and lower unit costs can be achieved with decreasing component densities. Especially when hot isostatic pressing is considered as a post-processing step. In order to be able to generate process parameters automatically, a model hypothesis is learned via artificial neural networks (ANN) for a density range from 70% to almost 100%, based on a synthetic dataset with equally distributed process parameters and a statistical test series with 256 full factorial combined instances. This allows the achievable relative density to be predicted from given process parameters. Based on the best model, a database approach and supervised training of concatenated ANNs are developed to solve the inverse parameter prediction problem for a target density. In this way, it is possible to generate a parameter prediction model for the high-dimensional result space through constraints that are shown with synthetic test data sets. The presented concatenated ANN model is able to reproduce the origin distribution. The relative density of synthetic data can be predicted with an R2-value of 0.98. The mean build rate can be increased by 12% with the formulation of a hint during the backward model training. The application of the experimental data shows increased fuzziness related to the big data gaps and a small number of instances. For practical use, this algorithm could be trained on increased data sets and can be expanded by properties such as surface quality, residual stress, or mechanical strength. With knowledge of the necessary (mechanical) properties of the components, the model can be used to generate appropriate process parameters. This way, the processing time and the amount of scrap parts can be reduced.

Taxonomy of Damage Patterns in Composite Materials, Measuring Signals, and Methods for Automated Damage Diagnostics.

Due to the increasing use of the different composite materials in lightweight applications, such as in aerospace, it becomes crucial to understand the different damages occurring within them during life cycle and their possible inspection with different inspection techniques in different life cycle stages. A comprehensive classification of these damage patterns, measuring signals, and analysis methods using a taxonomical approach can help in this direction. In conjunction with the taxonomy, this work addresses damage diagnostics in hybrid and composite materials, such as fibre metal laminates (FMLs). A novel unified taxonomy atlas of damage patterns, measuring signals, and analysis methods is introduced. Analysis methods based on advanced supervised and unsupervised machine learning algorithms, such as autoencoders, self-organising maps, and convolutional neural networks, and a novel z-profiling method, are implemented. Besides formal aspects, an extended use case demonstrating damage identification in FML plates using X-ray computer tomography (X-ray CT) data is used to elaborate different data analysis techniques to amplify or detect damages and to show challenges.

Real-Time Human-In-The-Loop Simulation with Mobile Agents, Chat Bots, and Crowd Sensing for Smart Cities.

Modelling and simulation of social interaction and networks are of high interest in multiple disciplines and fields of application ranging from fundamental social sciences to smart city management. Future smart city infrastructures and management are characterised by adaptive and self-organising control using real-world sensor data. In this work, humans are considered as sensors. Virtual worlds, e.g., simulations and games, are commonly closed and rely on artificial social behaviour and synthetic sensor information generated by the simulator program or using data collected off-line by surveys. In contrast, real worlds have a higher diversity. Agent-based modelling relies on parameterised models. The selection of suitable parameter sets is crucial to match real-world behaviour. In this work, a framework combining agent-based simulation with crowd sensing and social data mining using mobile agents is introduced. The crowd sensing via chat bots creates augmented virtuality and reality by augmenting the simulated worlds with real-world interaction and vice versa. The simulated world interacts with real-world environments, humans, machines, and other virtual worlds in real-time. Among the mining of physical sensors (e.g., temperature, motion, position, and light) of mobile devices like smartphones, mobile agents can perform crowd sensing by participating in question-answer dialogues via a chat blog (provided by smartphone Apps or integrated into WEB pages and social media). Additionally, mobile agents can act as virtual sensors (offering data exchanged with other agents) and create a bridge between virtual and real worlds. The ubiquitous usage of digital social media has relevant impact on social interaction, mobility, and opinion-making, which has to be considered. Three different use-cases demonstrate the suitability of augmented agent-based simulation for social network analysis using parameterised behavioural models and mobile agent-based crowd sensing. This paper gives a rigorous overview and introduction of the challenges and methodologies used to study and control large-scale and complex socio-technical systems using agent-based methods.

Cloud-Based Automated Design and Additive Manufacturing: A Usage Data-Enabled Paradigm Shift.

Integration of sensors into various kinds of products and machines provides access to in-depth usage information as basis for product optimization. Presently, this large potential for more user-friendly and efficient products is not being realized because (a) sensor integration and thus usage information is not available on a large scale and (b) product optimization requires considerable efforts in terms of manpower and adaptation of production equipment. However, with the advent of cloud-based services and highly flexible additive manufacturing techniques, these obstacles are currently crumbling away at rapid pace. The present study explores the state of the art in gathering and evaluating product usage and life cycle data, additive manufacturing and sensor integration, automated design and cloud-based services in manufacturing. By joining and extrapolating development trends in these areas, it delimits the foundations of a manufacturing concept that will allow continuous and economically viable product optimization on a general, user group or individual user level. This projection is checked against three different application scenarios, each of which stresses different aspects of the underlying holistic concept. The following discussion identifies critical issues and research needs by adopting the relevant stakeholder perspectives.

Design and simulation of material-integrated distributed sensor processing with a code-based agent platform and mobile multi-agent systems.

Multi-agent systems (MAS) can be used for decentralized and self-organizing data processing in a distributed system, like a resource-constrained sensor network, enabling distributed information extraction, for example, based on pattern recognition and self-organization, by decomposing complex tasks in simpler cooperative agents. Reliable MAS-based data processing approaches can aid the material-integration of structural-monitoring applications, with agent processing platforms scaled to the microchip level. The agent behavior, based on a dynamic activity-transition graph (ATG) model, is implemented with program code storing the control and the data state of an agent, which is novel. The program code can be modified by the agent itself using code morphing techniques and is capable of migrating in the network between nodes. The program code is a self-contained unit (a container) and embeds the agent data, the initialization instructions and the ATG behavior implementation. The microchip agent processing platform used for the execution of the agent code is a standalone multi-core stack machine with a zero-operand instruction format, leading to a small-sized agent program code, low system complexity and high system performance. The agent processing is token-queue-based, similar to Petri-nets. The agent platform can be implemented in software, too, offering compatibility at the operational and code level, supporting agent processing in strong heterogeneous networks. In this work, the agent platform embedded in a large-scale distributed sensor network is simulated at the architectural level by using agent-based simulation techniques.