In-situ process monitoring for defect detection in wire-arc additive manufacturing: an agentic AI approach

Abstract: AI agents are being increasingly deployed across a wide range of real-world applications. In this paper, we propose an agentic AI framework for in-situ process monitoring for defect detection in wire-arc additive manufacturing (WAAM). The autonomous agent leverages a WAAM process monitoring dataset and a trained classification tool to build AI agents and uses a LLM for in-situ process monitoring decision-making for defect detection. A processing agent is developed based on welder process signals, such as current and voltage, and a monitoring agent is developed based on acoustic data collected during the process. Both agents are tasked with identifying porosity defects from processing and monitoring signals, respectively. Ground truth X-ray computed tomography (XCT) data are used to develop classification tools for both the processing and monitoring agents. Furthermore, a multi-agent framework is demonstrated in which the processing and monitoring agents are orchestrated together for parallel decision-making on the given task of defect classification. Evaluation metrics are proposed to determine the efficacy of both individual agents, the combined single-agent, and the coordinated multi-agent system. The multi-agent configuration outperforms all individual-agent counterparts, achieving a decision accuracy of 91.6% and an F1 score of 0.821 on decided runs, across 15 independent runs, and a reasoning quality score of 3.74 out of 5. These in-situ process monitoring agents hold significant potential for autonomous real-time process monitoring and control toward building qualified parts for WAAM and other additive manufacturing processes.