A preliminary data fusion study to assess the feasibility of Foundation Process-Property Models in Laser Powder Bed Fusion

Foundation models are at the forefront of an increasing number of critical applications. In regards to technologies such as additive manufacturing (AM), these models have the potential to dramatically accelerate process optimization and, in turn, design of next generation materials. A major challenge that impedes the construction of foundation process-property models is data scarcity. To understand the impact of this challenge, and since foundation models rely on data fusion, in this work we conduct controlled experiments where we focus on the transferability of information across different material systems and properties. More specifically, we generate experimental datasets from 17-4 PH and 316L stainless steels (SSs) in Laser Powder Bed Fusion (LPBF) where we measure the effect of five process parameters on porosity and hardness. We then leverage Gaussian processes (GPs) for process-property modeling in various configurations to test if knowledge about one material system or property can be leveraged to build more accurate machine learning models for other material systems or properties. Through extensive cross-validation studies and probing the GPs' interpretable hyperparameters, we study the intricate relation among data size and dimensionality, complexity of the process-property relations, noise, and characteristics of machine learning models. Our findings highlight the need for structured learning approaches that incorporate domain knowledge in building foundation process-property models rather than relying on uninformed data fusion in data-limited applications.