[{"year":"2026","title":"A physics-guided hybrid framework for online pre-expulsion prediction in resistance spot welding","publication_identifier":{"issn":["1526-6125"]},"author":[{"id":"65085","full_name":"Yang, Keke","orcid":"0000-0001-9201-9304","last_name":"Yang","first_name":"Keke"},{"first_name":"Chong","last_name":"Li","full_name":"Li, Chong"},{"full_name":"Beck, Robert","last_name":"Beck","orcid":"0000-0001-9056-4528","first_name":"Robert","id":"38279"},{"full_name":"Hein, David","last_name":"Hein","first_name":"David","id":"7728"},{"id":"32056","full_name":"Meschut, Gerson","last_name":"Meschut","first_name":"Gerson","orcid":"0000-0002-2763-1246"}],"date_updated":"2026-07-18T12:07:50Z","publication_status":"published","intvolume":"       174","article_type":"original","main_file_link":[{"open_access":"1"}],"language":[{"iso":"eng"}],"doi":"10.1016/j.jmapro.2026.07.042","publication":"Journal of Manufacturing Processes","abstract":[{"lang":"eng","text":"Expulsion in resistance spot welding (RSW) causes weld quality fluctuations and increases quality-control effort in high-volume manufacturing. Existing data-driven studies have mainly addressed post-occurrence expulsion detection, process-end classification, or the identification of influencing factors, whereas online monitoring requires short-term risk estimation before the event occurs. In this study, expulsion prediction is formulated as a sliding-window-based pre-expulsion risk estimation task for the currently welded spot. A physics-guided hybrid GRU-XGBoost ensemble is developed to combine temporal learning from dynamic resistance and electrode-force signals with process-physics-related scalar features describing heat input, resistance state, and force response. The framework was evaluated on 2730 valid welds, including 588 expulsion and 2142 non-expulsion welds, using weld-grouped five-fold cross-validation with fold-level working-point selection. The ensemble achieved an area under the ROC curve of 0.945 ± 0.004 and a weld-level recall of 90.6 ± 3.7% at an average false alarm rate of 9.8 ± 0.2%, outperforming both individual branches. For the 533 correctly warned expulsion welds, the median early-warning lead time was 56 ms. These results indicate that online, physically interpretable pre-expulsion risk prediction is feasible under low-false-alarm constraints within the investigated RSW configuration and provide a basis for future adaptive monitoring and control studies."}],"file":[{"creator":"kekeyang","date_created":"2026-07-18T12:04:02Z","relation":"main_file","date_updated":"2026-07-18T12:04:02Z","file_name":"1-s2.0-S1526612526007012-main.pdf","access_level":"closed","file_size":10864983,"file_id":"66542","content_type":"application/pdf","success":1}],"date_created":"2026-07-18T12:03:15Z","keyword":["Resistance spot welding","Expulsion prediction","Physics-guided machine learning","Hybrid ensemble modelling","Process monitoring"],"type":"journal_article","department":[{"_id":"157"}],"status":"public","has_accepted_license":"1","page":"135-153","publisher":"Elsevier BV","_id":"66541","ddc":["600"],"user_id":"65085","volume":174,"file_date_updated":"2026-07-18T12:04:02Z","citation":{"ama":"Yang K, Li C, Beck R, Hein D, Meschut G. A physics-guided hybrid framework for online pre-expulsion prediction in resistance spot welding. <i>Journal of Manufacturing Processes</i>. 2026;174:135-153. doi:<a href=\"https://doi.org/10.1016/j.jmapro.2026.07.042\">10.1016/j.jmapro.2026.07.042</a>","bibtex":"@article{Yang_Li_Beck_Hein_Meschut_2026, title={A physics-guided hybrid framework for online pre-expulsion prediction in resistance spot welding}, volume={174}, DOI={<a href=\"https://doi.org/10.1016/j.jmapro.2026.07.042\">10.1016/j.jmapro.2026.07.042</a>}, journal={Journal of Manufacturing Processes}, publisher={Elsevier BV}, author={Yang, Keke and Li, Chong and Beck, Robert and Hein, David and Meschut, Gerson}, year={2026}, pages={135–153} }","mla":"Yang, Keke, et al. “A Physics-Guided Hybrid Framework for Online Pre-Expulsion Prediction in Resistance Spot Welding.” <i>Journal of Manufacturing Processes</i>, vol. 174, Elsevier BV, 2026, pp. 135–53, doi:<a href=\"https://doi.org/10.1016/j.jmapro.2026.07.042\">10.1016/j.jmapro.2026.07.042</a>.","chicago":"Yang, Keke, Chong Li, Robert Beck, David Hein, and Gerson Meschut. “A Physics-Guided Hybrid Framework for Online Pre-Expulsion Prediction in Resistance Spot Welding.” <i>Journal of Manufacturing Processes</i> 174 (2026): 135–53. <a href=\"https://doi.org/10.1016/j.jmapro.2026.07.042\">https://doi.org/10.1016/j.jmapro.2026.07.042</a>.","short":"K. Yang, C. Li, R. Beck, D. Hein, G. Meschut, Journal of Manufacturing Processes 174 (2026) 135–153.","apa":"Yang, K., Li, C., Beck, R., Hein, D., &#38; Meschut, G. (2026). A physics-guided hybrid framework for online pre-expulsion prediction in resistance spot welding. <i>Journal of Manufacturing Processes</i>, <i>174</i>, 135–153. <a href=\"https://doi.org/10.1016/j.jmapro.2026.07.042\">https://doi.org/10.1016/j.jmapro.2026.07.042</a>","ieee":"K. Yang, C. Li, R. Beck, D. Hein, and G. Meschut, “A physics-guided hybrid framework for online pre-expulsion prediction in resistance spot welding,” <i>Journal of Manufacturing Processes</i>, vol. 174, pp. 135–153, 2026, doi: <a href=\"https://doi.org/10.1016/j.jmapro.2026.07.042\">10.1016/j.jmapro.2026.07.042</a>."},"quality_controlled":"1","oa":"1"},{"publication":"Proceedings of the 33nd Annual International Solid Freeform Fabrication Symposium","citation":{"ama":"Klippstein SH, Schmid H-J. Powder Spread Flaws in Polymer Laser Sintering and its Influences on Mechanical Performance. In: <i>Proceedings of the 33nd Annual International Solid Freeform Fabrication Symposium</i>. ; 2022.","bibtex":"@inproceedings{Klippstein_Schmid_2022, place={Austin, TX, USA}, title={Powder Spread Flaws in Polymer Laser Sintering and its Influences on Mechanical Performance}, booktitle={Proceedings of the 33nd Annual International Solid Freeform Fabrication Symposium}, author={Klippstein, Sven Helge and Schmid, Hans-Joachim}, year={2022} }","mla":"Klippstein, Sven Helge, and Hans-Joachim Schmid. “Powder Spread Flaws in Polymer Laser Sintering and Its Influences on Mechanical Performance.” <i>Proceedings of the 33nd Annual International Solid Freeform Fabrication Symposium</i>, 2022.","short":"S.H. Klippstein, H.-J. Schmid, in: Proceedings of the 33nd Annual International Solid Freeform Fabrication Symposium, Austin, TX, USA, 2022.","chicago":"Klippstein, Sven Helge, and Hans-Joachim Schmid. “Powder Spread Flaws in Polymer Laser Sintering and Its Influences on Mechanical Performance.” In <i>Proceedings of the 33nd Annual International Solid Freeform Fabrication Symposium</i>. Austin, TX, USA, 2022.","apa":"Klippstein, S. H., &#38; Schmid, H.-J. (2022). Powder Spread Flaws in Polymer Laser Sintering and its Influences on Mechanical Performance. <i>Proceedings of the 33nd Annual International Solid Freeform Fabrication Symposium</i>.","ieee":"S. H. Klippstein and H.-J. Schmid, “Powder Spread Flaws in Polymer Laser Sintering and its Influences on Mechanical Performance,” 2022."},"quality_controlled":"1","abstract":[{"text":"By monitoring the recoating process within polymer laser sintering production, it was shown that multiple powder-spread-flaws can be detected. Those groove-like flaws are expected to be the result of agglomerates jamming between the recoater and the last powder layer. This work is analyzing the interaction between powder-spread-flaws and part properties, showing the influence of the recoating process on the performance of laser sintering parts. Therefore, artificial powder-spread-flaws are applied to the build jobs of tensile test specimens which are measured and analyzed regarding the elongation at break, strength and fracture position. For the characteristics of the flaws, the artificial grooves are varied in depth and width. Furthermore, the position of the flaw is changed form mid part to close to surface areas. It was shown, that several flaws are visible at the part surface, resulting in stress concentration and reduced performance. But there are as well parts with flaw-layers, which are not visible after the build process on the part. Those parts can have significantly reduced mechanical properties as well.","lang":"eng"}],"place":"Austin, TX, USA","date_created":"2022-09-13T16:42:10Z","type":"conference","keyword":["Selective Sasersintering","Process Monitoring","Powder Spread"],"oa":"1","department":[{"_id":"150"},{"_id":"624"},{"_id":"219"}],"status":"public","title":"Powder Spread Flaws in Polymer Laser Sintering and its Influences on Mechanical Performance","year":"2022","author":[{"id":"71545","first_name":"Sven Helge","last_name":"Klippstein","full_name":"Klippstein, Sven Helge"},{"full_name":"Schmid, Hans-Joachim","first_name":"Hans-Joachim","last_name":"Schmid","orcid":"000-0001-8590-1921","id":"464"}],"date_updated":"2023-05-04T08:31:49Z","main_file_link":[{"url":"https://utw10945.utweb.utexas.edu/sites/default/files/2022/Powder%20Spread%20Flaws%20in%20Polymer%20Laser%20Sintering%20and.pdf","open_access":"1"}],"_id":"33356","language":[{"iso":"eng"}],"user_id":"464"},{"abstract":[{"text":"To optimize the ultrasound irradiation for cavitation based ultrasound applications like sonochemistry or ultrasound cleaning, the correlation between cavitation intensity and the resulting effect on the process is of interest. Furthermore, changing conditions like temperature and pressure result in varying acoustic properties of the liquid. That might necessitate an adaption of the ultrasound irradiation. To detect such changes during operation, process monitoring is desired. Labor intensive processes, that might be carried out for several hours, also require process monitoring to increase their reliability by detection of changes or malfunctions during operation. In some applications cavitation detection and monitoring can be achieved by the application of sensors in the sound field. Though the application of sensors is possible, this necessitates modifications on the system and the sensor might disturb the sound field. In other applications harsh, process conditions prohibit the application of sensors in the sound field. Therefore alternative techniques for cavitation detection and monitoring are desired. The applicability of an external microphone and a self-sensing ultrasound transducer for cavitation detection were experimentally investigated. Both methods were found to be suitable and easily applicable.","lang":"eng"}],"quality_controlled":"1","publication":"Ultrasonics Symposium (IUS), 2012 IEEE International","citation":{"bibtex":"@inproceedings{Bornmann_Hemsel_Sextro_Maeda_Morita_2012, title={Non-perturbing cavitation detection / monitoring in sonochemical reactors}, DOI={<a href=\"https://doi.org/10.1109/ULTSYM.2012.0284\">10.1109/ULTSYM.2012.0284</a>}, booktitle={Ultrasonics Symposium (IUS), 2012 IEEE International}, author={Bornmann, Peter and Hemsel, Tobias and Sextro, Walter and Maeda, Takafumi and Morita, Takeshi}, year={2012}, pages={1141–1144} }","chicago":"Bornmann, Peter, Tobias Hemsel, Walter Sextro, Takafumi Maeda, and Takeshi Morita. “Non-Perturbing Cavitation Detection / Monitoring in Sonochemical Reactors.” In <i>Ultrasonics Symposium (IUS), 2012 IEEE International</i>, 1141–44, 2012. <a href=\"https://doi.org/10.1109/ULTSYM.2012.0284\">https://doi.org/10.1109/ULTSYM.2012.0284</a>.","ama":"Bornmann P, Hemsel T, Sextro W, Maeda T, Morita T. Non-perturbing cavitation detection / monitoring in sonochemical reactors. In: <i>Ultrasonics Symposium (IUS), 2012 IEEE International</i>. ; 2012:1141-1144. doi:<a href=\"https://doi.org/10.1109/ULTSYM.2012.0284\">10.1109/ULTSYM.2012.0284</a>","short":"P. Bornmann, T. Hemsel, W. Sextro, T. Maeda, T. Morita, in: Ultrasonics Symposium (IUS), 2012 IEEE International, 2012, pp. 1141–1144.","ieee":"P. Bornmann, T. Hemsel, W. Sextro, T. Maeda, and T. Morita, “Non-perturbing cavitation detection / monitoring in sonochemical reactors,” in <i>Ultrasonics Symposium (IUS), 2012 IEEE International</i>, 2012, pp. 1141–1144.","mla":"Bornmann, Peter, et al. “Non-Perturbing Cavitation Detection / Monitoring in Sonochemical Reactors.” <i>Ultrasonics Symposium (IUS), 2012 IEEE International</i>, 2012, pp. 1141–44, doi:<a href=\"https://doi.org/10.1109/ULTSYM.2012.0284\">10.1109/ULTSYM.2012.0284</a>.","apa":"Bornmann, P., Hemsel, T., Sextro, W., Maeda, T., &#38; Morita, T. (2012). Non-perturbing cavitation detection / monitoring in sonochemical reactors. In <i>Ultrasonics Symposium (IUS), 2012 IEEE International</i> (pp. 1141–1144). <a href=\"https://doi.org/10.1109/ULTSYM.2012.0284\">https://doi.org/10.1109/ULTSYM.2012.0284</a>"},"type":"conference","keyword":["cavitation","chemical reactors","microphones","process monitoring","reliability","ultrasonic applications","ultrasonic waves","acoustic properties","cavitation based ultrasound applications","cavitation intensity","change detection reliability","external microphone","malfunction detection reliability","nonperturbing cavitation detection","nonperturbing cavitation monitoring","process monitoring","self-sensing ultrasound transducer","sonochemical reactors","sonochemistry","ultrasound cleaning","ultrasound irradiation","Acoustics","Liquids","Monitoring","Sensors","Sonar equipment","Transducers","Ultrasonic imaging"],"department":[{"_id":"151"}],"date_created":"2019-05-13T13:18:49Z","date_updated":"2022-01-06T07:04:20Z","year":"2012","title":"Non-perturbing cavitation detection / monitoring in sonochemical reactors","status":"public","publication_identifier":{"issn":["1948-5719"]},"author":[{"full_name":"Bornmann, Peter","last_name":"Bornmann","first_name":"Peter"},{"id":"210","full_name":"Hemsel, Tobias","first_name":"Tobias","last_name":"Hemsel"},{"id":"21220","first_name":"Walter","last_name":"Sextro","full_name":"Sextro, Walter"},{"first_name":"Takafumi","last_name":"Maeda","full_name":"Maeda, Takafumi"},{"full_name":"Morita, Takeshi","first_name":"Takeshi","last_name":"Morita"}],"doi":"10.1109/ULTSYM.2012.0284","user_id":"55222","page":"1141-1144","language":[{"iso":"eng"}],"_id":"9783"}]