A1 Refereed original research article in a scientific journal
Advances in machine learning for parameters optimisation and in-situ monitoring of wire arc additive manufacturing
Authors: Mattera, Gulio; Chozaki, Saeid Parchegani; Norrish, John
Publisher: SPRINGER HEIDELBERG
Publication year: 2025
Journal: Welding in the World
ISSN: 0043-2288
eISSN: 1878-6669
DOI: https://doi.org/10.1007/s40194-025-02200-5
Publication's open availability at the time of reporting: Open Access
Publication channel's open availability : Partially Open Access publication channel
Web address : https://doi.org/10.1007/s40194-025-02200-5
Self-archived copy’s web address: https://research.utu.fi/converis/portal/detail/Publication/505617622
Wire arc additive manufacturing (WAAM) demands both real-time monitoring of process stabi-supervised learning for real-time anomility and defects and offline optimisation of process parameters to guarantee part quality and production efficiency. This review critically surveys recent machine learning (ML) techniques for in situ monitoring and parameter optimisation in WAAM, with an emphasis on the integration of ML and bio-inspired optimisation algorithms. In relation to in-situ monitoring, this review examines the roles of supervised and unsupervised learning, as well as advanced deep-learning architectures-such as generative AI and frequency-informed neural networks-in processing welding current and welding voltage, as well as vision-based, audible, acoustic-emission, and thermal imaging data. Furthermore, this paper surveys the latest developments in bio-inspired optimisation models applied to WAAM, discussing how ML-enabled frameworks can enhance sustainability and efficiency metrics in the offline selection of optimal process parameters. The synthesis of insights at the end of each section establishes a structured framework for practitioners, highlights existing research gaps, and outlines strategic directions for future advancements in ML-driven WAAM monitoring and optimisation.
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Funding information in the publication:
Open access funding provided by Università degli Studi di Napoli Federico II within the CRUI-CARE Agreement.
