深度学习辅助搅拌摩擦增材制造研究综述

A review of deep learning-assisted friction stir additive manufacturing research

  • 摘要: 搅拌摩擦增材制造(friction stir additive manufacturing, FSAM)作为一种新兴的固相增材制造技术,在高温合金、复合材料和超大型零件一体化等难加工领域展现出显著的应用潜力。该工艺过程涉及复杂的热-力-材料多场耦合效应,工艺参数与成形质量之间呈强非线性关系,为其工艺优化与控制带来巨大挑战。近年来,深度学习凭借其在复杂数据挖掘与非线性建模方面的强大能力,为FSAM工艺链的智能化发展提供了新的研究路径,通过构建端到端的智能模型系统,实现了对多源异构工艺数据的高维特征自动提取与融合解析,突破了传统方法在非线性关系建模、动态过程适应性及多目标协同优化等方面的固有局限,从而为工艺稳定性提升与微观组织精准调控提供了前所未有的技术路径。对深度学习在搅拌摩擦增材制造中的研究进展进行了系统综述。首先阐明了FSAM工艺原理与微观演化机理,紧接着对过程中所涉及的多源数据进行分类梳理,进而重点探讨深度学习在过程监测与缺陷检测、参数预测与性能分析、微观组织演化预测以及过程优化策略等关键方向的应用成果。综合现有研究表明,尽管深度学习已在提升FSAM工艺可控性与预测精度方面取得显著成效,但仍面临多源数据匮乏、模型可解释性不足、跨工艺场景泛化能力有限等核心挑战。由此可见,深度学习在FSAM领域的深入融合与推广应用,仍具有广阔的研究空间与发展潜力。

     

    Abstract: Friction stir additive manufacturing (FSAM), as an emerging solid-state additive manufacturing technology, has demonstrated significant application potential in difficult-to-process fields such as high-temperature alloys, composite materials, and integrated fabrication of ultra-large components. The process involves complex thermo-mechanical-material multi-field coupling effects, and the relationship between process parameters and forming quality exhibits strong nonlinear characteristics, posing major challenges for process optimization and control. In recent years, deep learning has provided new research avenues for the intelligent development of the FSAM process chain due to its powerful capabilities in complex data mining and nonlinear modeling. By constructing end-to-end intelligent model systems, it enables the automatic extraction and integrated analysis of high-dimensional features from multi-source heterogeneous process data, overcoming the inherent limitations of traditional methods in modeling nonlinear relationships, dynamic process adaptability, and multi-objective collaborative optimization. Unprecedented technical pathways for enhancing process stability and precisely controlling microstructural evolution have been thereby offered. A systematic review of research progress in deep learning applications for friction stir additive manufacturing is presented. Fundamental principles and microstructural evolution mechanisms of the FSAM process are first elucidated, followed by systematic classification and organization of the multi-source data involved. Subsequently, application outcomes of deep learning are focused on across several key domains, including process monitoring and defect detection, parameter prediction and performance analysis, prediction of microstructural evolution, and process optimization strategies. Comprehensive analysis of existing research indicates that although remarkable success has been achieved by deep learning in enhancing the controllability and prediction accuracy of the FSAM process, core challenges are still faced, such as scarcity of multi-source data, insufficient model interpretability, and limited generalization ability across different process scenarios. Thus, extensive research opportunities and development potential remain for the deep integration and broader application of deep learning in the FSAM field.

     

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