Data-driven discovery of dimensionless numbers and governing laws from scarce measurements.

Dimensionless numbers and scaling laws provide elegant insights into the characteristic properties of physical systems. Classical dimensional analysis and similitude theory fail to identify a set of unique dimensionless numbers for a highly multi-variable system with incomplete governing equations. This paper introduces a mechanistic data-driven approach that embeds the principle of dimensional invariance into a two-level machine learning scheme to automatically discover dominant dimensionless numbers and governing laws (including scaling laws and differential equations) from scarce measurement data. The proposed methodology, called dimensionless learning, is a physics-based dimension reduction technique. It can reduce high-dimensional parameter spaces to descriptions involving only a few physically interpretable dimensionless parameters, greatly simplifying complex process design and system optimization. We demonstrate the algorithm by solving several challenging engineering problems with noisy experimental measurements (not synthetic data) collected from the literature. Examples include turbulent Rayleigh-Bénard convection, vapor depression dynamics in laser melting of metals, and porosity formation in 3D printing. Lastly, we show that the proposed approach can identify dimensionally homogeneous differential equations with dimensionless number(s) by leveraging sparsity-promoting techniques.

Universal scaling laws of keyhole stability and porosity in 3D printing of metals.

Metal three-dimensional (3D) printing includes a vast number of operation and material parameters with complex dependencies, which significantly complicates process optimization, materials development, and real-time monitoring and control. We leverage ultrahigh-speed synchrotron X-ray imaging and high-fidelity multiphysics modeling to identify simple yet universal scaling laws for keyhole stability and porosity in metal 3D printing. The laws apply broadly and remain accurate for different materials, processing conditions, and printing machines. We define a dimensionless number, the Keyhole number, to predict aspect ratio of a keyhole and the morphological transition from stable at low Keyhole number to chaotic at high Keyhole number. Furthermore, we discover inherent correlation between keyhole stability and porosity formation in metal 3D printing. By reducing the dimensions of the formulation of these challenging problems, the compact scaling laws will aid process optimization and defect elimination during metal 3D printing, and potentially lead to a quantitative predictive framework.