Federated Learning-Enabled Secure Multi-Modal Anomaly Detection for Wire Arc Additive Manufacturing

This paper presents a federated learning (FL) architecture tailored for anomaly detection in wire arc additive manufacturing (WAAM) that preserves data privacy while enabling secure and distributed model training across heterogeneous process units. WAAM’s inherent process complexity, characterized by high-dimensional and asynchronous sensor streams, including current, voltage, travel speed, and visual bead profiles, necessitates a decentralized learning paradigm capable of handling non-identical client distributions without raw data pooling. To this end, the proposed framework integrates reversible data hiding in the encrypted domain (RDHE) for the secure embedding of sensor-derived features into weld images, enabling confidential parameter transmission and tamper-evident federation. Each client node employs a domain-specific long short-term memory (LSTM)-based classifier trained on locally curated time-series or vision-derived features, with model updates embedded and transmitted securely to a central aggregator. Three FL strategies, FedAvg, FedProx, and FedPer, are systematically evaluated against four robust aggregation techniques, including KRUM, Multi-KRUM, and Trimmed Mean, across 100 communication rounds using eight non-independent and identically distributed (non-IID) WAAM clients. Experimental results reveal that FedPer coupled with Trimmed Mean delivers the optimal configuration, achieving maximum F1-score (0.912), area under the curve (AUC) (0.939), and client-wise generalization stability under both geometric and temporal noise. The proposed approach demonstrates near-lossless RDHE encoding (PSNR > 90 dB) and robust convergence across adversarial conditions. By embedding encrypted intelligence within weld imagery and tailoring FL to WAAM-specific signal variability, this study introduces a scalable, secure, and generalizable framework for process monitoring. These findings establish a baseline for federated anomaly detection in metal additive manufacturing, with implications for deploying privacy-preserving intelligence across smart manufacturing networks.