Accurately predicting the temperature field in metal additive manufacturing (AM) processes is critical to preventing overheating, adjusting process parameters, and ensuring process stability. While physics-based computational models offer precision, they are often time-consuming and unsuitable for real-time predictions and online control in iterative design scenarios. Conversely, machine learning models rely heavily on high-quality datasets, which can be costly and challenging to obtain within the metal AM domain. Our work addresses this by introducing a physics-informed neural network framework specifically designed for temperature field prediction in metal AM. This framework incorporates a physics-informed input, physics-informed loss function, and a Convolutional Long Short-Term Memory (ConvLSTM) architecture. Utilizing real-time temperature data from the process, our model predicts 2D temperature fields for future timestamps across diverse geometries, deposition patterns, and process parameters. We validate the proposed framework in two scenarios: full-field temperature prediction for a thin wall and 2D temperature field prediction for cylinder and cubic parts, demonstrating errors below 3% and 1%, respectively. Our proposed framework exhibits the flexibility to be applied across diverse scenarios with varying process parameters, geometries, and deposition patterns.

Temperature field prediction is of great importance in the thermal design of systems engineering, and building the surrogate model is an effective way for the task. Generally, large amounts of labeled data are required to guarantee a good prediction performance of the surrogate model, especially the deep learning model, which have more parameters and better representational ability. However, labeled data, especially high-fidelity labeled data, are usually expensive to obtain and sometimes even impossible. To solve this problem, this paper proposes a pithy deep multi-fidelity model (DMFM) for temperature field prediction, which takes advantage of low-fidelity data to boost the performance with less high-fidelity data. First, a pre-train and fine-tune paradigm are developed in DMFM to train the low-fidelity and high-fidelity data, which significantly reduces the complexity of the deep surrogate model. Then, a self-supervised learning method for training the physics-driven deep multi-fidelity model (PD-DMFM) is proposed, which fully utilizes the physics characteristics of the engineering systems and reduces the dependence on large amounts of labeled low-fidelity data in the training process. Two diverse temperature field prediction problems are constructed to validate the effectiveness of DMFM and PD-DMFM, and the result shows that the proposed method can greatly reduce the dependence of the model on high-fidelity data.

Recently, surrogate models based on deep learning have attracted much attention for engineering analysis and optimization. As the construction of data pairs in most engineering problems is time-consuming, data acquisition is becoming the predictive capability bottleneck of most deep surrogate models, which also exists in surrogate for thermal analysis and design. To address this issue, this paper develops a physics-informed convolutional neural network (CNN) for the thermal simulation surrogate. The network can learn a mapping from heat source layout to the steady-state temperature field without labeled data, which equals solving an entire family of partial difference equations (PDEs). To realize the physics-guided training without labeled data, we employ the heat conduction equation and finite difference method to construct the loss function. Since the solution is sensitive to boundary conditions, we properly impose hard constraints by padding in the Dirichlet and Neumann boundary conditions. In addition, the neural network architecture is well-designed to improve the prediction precision of the problem at hand, and pixel-level online hard example mining is introduced to overcome the imbalance of optimization difficulty in the computation domain. The experiments demonstrate that the proposed method can provide comparable predictions with numerical method and data-driven deep learning models. We also conduct various ablation studies to investigate the effectiveness of the network component and training methods proposed in this paper.

Thermal issue is of great importance during layout design of heat source components in systems engineering, especially for high functional-density products. Thermal analysis generally needs complex simulation, which leads to an unaffordable computational burden to layout optimization as it iteratively evaluates different schemes. Surrogate modeling is an effective way to alleviate computation complexity. However, temperature field prediction (TFP) with complex heat source layout (HSL) input is an ultra-high dimensional nonlinear regression problem, which brings great difficulty to traditional regression models. The Deep neural network (DNN) regression method is a feasible way for its good approximation performance. However, it faces great challenges in both data preparation for sample diversity and uniformity in the layout space with physical constraints, and proper DNN model selection and training for good generality, which necessitates efforts of both layout designer and DNN experts. To advance this cross-domain research, this paper proposes a DNN based HSL-TFP surrogate modeling task benchmark. With consideration for engineering applicability, sample generation, dataset evaluation, DNN model, and surrogate performance metrics, are thoroughly studied. Experiments are conducted with ten representative state-of-the-art DNN models. Detailed discussion on baseline results is provided and future prospects are analyzed for DNN based HSL-TFP tasks.