Multi-physics information-integrated neural network for fatigue life prediction of additively manufactured Hastelloy X superalloy

The inherent 'black-box' characteristic of neural networks renders the physical interpretability of fatigue life prediction challenging, resulting in physically inconsistent prediction results. In response to this challenge, a multi-physics information-integrated neural network framework is proposed for fatigue life prediction. Rooted in the continuous damage mechanics with embedded additive manufacturing process parameters (AM-CDM), coupled with activation functions and loss functions that amalgamate physical information, a multi-tiered and multi-physical information source network framework emerges. The framework incorporates the outcomes of the AM-CDM model as input features for domain knowledge enhancement, embeds the fatigue limit within the activation function, and establishes a loss function integrating the physical model. Through the integration of multiple physical information, the model can be restricted by different physical constraints during training, thereby improving its prediction accuracy and physical consistency. Validation of the proposed framework is conducted using laser powder bed fusion (LPBF)-fabricated Hastelloy X subjected to varying orientations, post-treatments and test temperatures. The findings demonstrate that the prediction accuracy of an integrating-physics-informed neural network (IPINN) is improved by 27.51%, and its life prediction results are capped at the fatigue limit life, yielding a better physical consistency. The IPINN framework provides a novel perspective for fatigue life prediction.