Porosity Prediction in Aluminum Wire Arc Additive Manufacturing Using Two-Stage Machine Learning Cascade and Computed Tomography
This study presents a two-stage machine learning cascade framework that correlates real-time CMT-WAAM process parameters with industrial CT-derived porosity data to predict and monitor internal defects in aluminum components, achieving an F1 score of 0.47 while offering a scalable solution for in-situ quality assurance.