Application of deep learning for automatic
classification of fracture surface’s SEM image.
Kenta Yamagiwa (kenta@yamagiwa.org)
Ph.D., Senior Researcher
Mechanics and System Safety Group,
National Institute for Occupational Safety and Health,
Japan
ICEFA08@Budapest, Hungary
Problems in Japan
• Number of people
– who are interested in
failure analysis
– can understand the
fracture surface
is decreasing.
• Qualitative analysis
– Low quality of fractography
– Wrong results lead wrong
countermeasures.
• Unstable operation.
ICEFA08@Budapest, Hungary
Supporting system of fractography
Current status
Human based
Future status
Machine based
ICEFA08@Budapest, Hungary !
Needless to work.
More beer and life elevated.
SEM (Scanning Electron Microscopy) of fracture surface
Ductile (Dimple) Brittle (Facet) Fatigue (Striation)
Feature of fracture surface depends on fracture mechanics.
They are quite different as you can see.
Is it possible to classify automatically?
ICEFA08@Budapest, Hungary
Classification of Images
Before classification After classification
DOGS
CATS
ICEFA08@Budapest, Hungary
Deep Learning
• Huge number of pictures
– Ex. More than 1 million.
• Deep layer of neural
network
• Supervised learning /
Unsupervised learning
• Needless to consider
characteristic
values/vectors like
roughness parameters for
the classification.
https://www.xenonstack.com/
ICEFA08@Budapest, Hungary
[Un] Supervised Learning
Supervised
• Need to train
• Text (previously classified)
for train is required.
Unsupervised
• Needless to train
• Text is not required.
Test data
Training data
Drawing the line
(Classification)
ICEFA08@Budapest, Hungary
Convolution Neural Network (CNN)
.
.
.
.
.
.
.
.
.
.
.
.
Convolution process (filters)
ICEFA08@Budapest, Hungary
2
4
0
5
8
3
6
1
7
9
image
number
Convolution Neural Network (CNN)
Fatigue
Brittle
Ductile
.
.
.
.
.
.
.
.
.
.
.
.
Convolution process (filters)
ICEFA08@Budapest, Hungary
Prob. = 0.2
Prob. = 0.1
Prob. = 0.7
Conditions
• Library: Tensorflow (https://www.tensorflow.org) by Google
• Machine: Mac mini (3GHz, Intel core i7, Memory 8G)
– Too poor…
• Method: CNN / Supervised Learning
– Hyper parameters: Learning rate=10-5, Image size = 32
• Number of classification: 3 (ductile, brittle, fatigue)
• Number of training images: 3132 (with augmentation)
– ductile: 972
– brittle: 572
– fatigue: 1588
• Number of test images: 214
– Ductile: 14
– Brittle: 150
– Fatigue: 50
ICEFA08@Budapest, Hungary
Calculation process
1. Training process by using training images
2. Obtaining Training Score
3. Testing process by using test images
4. Obtaining Testing Score
5. Return to the Training.
– Filter values in CNN is adjusted to reduce Error values.
Training
Score
Err val.
(Cross Entropy)
Testing
Score
CNN
CNN
CNN
CNN
CNN
CNN
D
D
F
F
B
D
Training Process
CNN
CNN
CNN
D
D
B
Testing Process
Changing filter values in CNN
ICEFA08@Budapest, Hungary
Next Step
0.5
0.6
0.7
0.8
0.9
1
1 10 100 1000
Score
Number of training
Training
Testing
ICEFA08@Budapest, Hungary
Result
Perfect score about 2k steps.
Finally, testing score is more than 0.9.
Result (correct classification)
Blue: Prob. of Fatigue
Green: Prob. of Brittle
Purple: Prob. of Ductile
The network judged the pic as fatigue
from the beginning.
Correct fracture mechanics Fracture mechanics detected by the network
ICEFA08@Budapest, Hungary
Result (correct classification)
Blue: Prob. of Fatigue
Green: Prob. of Brittle
Purple: Prob. of Ductile
Fatigue is negative from the beginning.
At first, the network judged the pic as brittle.
As the learning progressed, the network judged the pic as ductile.
ICEFA08@Budapest, Hungary
Result (misclassification)
Blue: Prob. of Fatigue
Green: Prob. of Brittle
Purple: Prob. of Ductile
Brittle is negative. Dithering over whether fatigue or ductile.
Different result
ICEFA08@Budapest, Hungary
Confusion matrix
Step = 1 Ductile Brittle Fatigue Trans-granular
Ductile 0 28 0 0
Brittle 0 150 0 0
Fatigue 0 56 0 0
Transgranular 0 14 0 0
Step = 500 Ductile Brittle Fatigue Trans-granular
Ductile 5 21 0 0
Brittle 1 149 0 0
Fatigue 0 0 56 0
Transgranular 0 0 0 14
Label of classification result
CorrectLabel
ICEFA08@Budapest, Hungary
Next step
• Appending other fracture
mechanics. Creep and
SCC(Inter/Trans granular).
• Application to the surfaces which
are difficult to estimate the load
(cat iron/aluminum)
• Application to non-metallic
materials (carbon composite).
• Automation for taking SEM
pictures.
Fatigue fracture surface of cast iron (FCD450)
ICEFA08@Budapest, Hungary
Conclusion
• Deep learning for automatic
classification of fracture surface’s
SEM image is well worked.
• It is enabled to support the
beginner engineer to make
decision for the detection of
fracture mechanics.
• More images and more deep
network, more calculation
resource are required.
ICEFA08@Budapest, Hungary
0.5
0.6
0.7
0.8
0.9
1
1 10 100 1000
Score
Number of training
Training
Testing
Acknowledgement
• ELIONIX (SEM manufacturer)
• Kiguchi Technics (Specimen)
• TDU students (Fatigue test)
• Thank you for paying your
attention.
ICEFA08@Budapest, Hungary

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Application of deep learning for automatic classification of fracture surface’s SEM image.

  • 1. Application of deep learning for automatic classification of fracture surface’s SEM image. Kenta Yamagiwa (kenta@yamagiwa.org) Ph.D., Senior Researcher Mechanics and System Safety Group, National Institute for Occupational Safety and Health, Japan ICEFA08@Budapest, Hungary
  • 2. Problems in Japan • Number of people – who are interested in failure analysis – can understand the fracture surface is decreasing. • Qualitative analysis – Low quality of fractography – Wrong results lead wrong countermeasures. • Unstable operation. ICEFA08@Budapest, Hungary
  • 3. Supporting system of fractography Current status Human based Future status Machine based ICEFA08@Budapest, Hungary ! Needless to work. More beer and life elevated.
  • 4. SEM (Scanning Electron Microscopy) of fracture surface Ductile (Dimple) Brittle (Facet) Fatigue (Striation) Feature of fracture surface depends on fracture mechanics. They are quite different as you can see. Is it possible to classify automatically? ICEFA08@Budapest, Hungary
  • 5. Classification of Images Before classification After classification DOGS CATS ICEFA08@Budapest, Hungary
  • 6. Deep Learning • Huge number of pictures – Ex. More than 1 million. • Deep layer of neural network • Supervised learning / Unsupervised learning • Needless to consider characteristic values/vectors like roughness parameters for the classification. https://www.xenonstack.com/ ICEFA08@Budapest, Hungary
  • 7. [Un] Supervised Learning Supervised • Need to train • Text (previously classified) for train is required. Unsupervised • Needless to train • Text is not required. Test data Training data Drawing the line (Classification) ICEFA08@Budapest, Hungary
  • 8. Convolution Neural Network (CNN) . . . . . . . . . . . . Convolution process (filters) ICEFA08@Budapest, Hungary 2 4 0 5 8 3 6 1 7 9 image number
  • 9. Convolution Neural Network (CNN) Fatigue Brittle Ductile . . . . . . . . . . . . Convolution process (filters) ICEFA08@Budapest, Hungary Prob. = 0.2 Prob. = 0.1 Prob. = 0.7
  • 10. Conditions • Library: Tensorflow (https://www.tensorflow.org) by Google • Machine: Mac mini (3GHz, Intel core i7, Memory 8G) – Too poor… • Method: CNN / Supervised Learning – Hyper parameters: Learning rate=10-5, Image size = 32 • Number of classification: 3 (ductile, brittle, fatigue) • Number of training images: 3132 (with augmentation) – ductile: 972 – brittle: 572 – fatigue: 1588 • Number of test images: 214 – Ductile: 14 – Brittle: 150 – Fatigue: 50 ICEFA08@Budapest, Hungary
  • 11. Calculation process 1. Training process by using training images 2. Obtaining Training Score 3. Testing process by using test images 4. Obtaining Testing Score 5. Return to the Training. – Filter values in CNN is adjusted to reduce Error values. Training Score Err val. (Cross Entropy) Testing Score CNN CNN CNN CNN CNN CNN D D F F B D Training Process CNN CNN CNN D D B Testing Process Changing filter values in CNN ICEFA08@Budapest, Hungary Next Step
  • 12. 0.5 0.6 0.7 0.8 0.9 1 1 10 100 1000 Score Number of training Training Testing ICEFA08@Budapest, Hungary Result Perfect score about 2k steps. Finally, testing score is more than 0.9.
  • 13. Result (correct classification) Blue: Prob. of Fatigue Green: Prob. of Brittle Purple: Prob. of Ductile The network judged the pic as fatigue from the beginning. Correct fracture mechanics Fracture mechanics detected by the network ICEFA08@Budapest, Hungary
  • 14. Result (correct classification) Blue: Prob. of Fatigue Green: Prob. of Brittle Purple: Prob. of Ductile Fatigue is negative from the beginning. At first, the network judged the pic as brittle. As the learning progressed, the network judged the pic as ductile. ICEFA08@Budapest, Hungary
  • 15. Result (misclassification) Blue: Prob. of Fatigue Green: Prob. of Brittle Purple: Prob. of Ductile Brittle is negative. Dithering over whether fatigue or ductile. Different result ICEFA08@Budapest, Hungary
  • 16. Confusion matrix Step = 1 Ductile Brittle Fatigue Trans-granular Ductile 0 28 0 0 Brittle 0 150 0 0 Fatigue 0 56 0 0 Transgranular 0 14 0 0 Step = 500 Ductile Brittle Fatigue Trans-granular Ductile 5 21 0 0 Brittle 1 149 0 0 Fatigue 0 0 56 0 Transgranular 0 0 0 14 Label of classification result CorrectLabel ICEFA08@Budapest, Hungary
  • 17. Next step • Appending other fracture mechanics. Creep and SCC(Inter/Trans granular). • Application to the surfaces which are difficult to estimate the load (cat iron/aluminum) • Application to non-metallic materials (carbon composite). • Automation for taking SEM pictures. Fatigue fracture surface of cast iron (FCD450) ICEFA08@Budapest, Hungary
  • 18. Conclusion • Deep learning for automatic classification of fracture surface’s SEM image is well worked. • It is enabled to support the beginner engineer to make decision for the detection of fracture mechanics. • More images and more deep network, more calculation resource are required. ICEFA08@Budapest, Hungary 0.5 0.6 0.7 0.8 0.9 1 1 10 100 1000 Score Number of training Training Testing
  • 19. Acknowledgement • ELIONIX (SEM manufacturer) • Kiguchi Technics (Specimen) • TDU students (Fatigue test) • Thank you for paying your attention. ICEFA08@Budapest, Hungary