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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Accurate and Fast Anomaly Detection in Additive Composite-Based Manufacturing using Thermal Cameras

Today, large-scale additive manufacturing with plastics and composite materials requires continuous monitoring by experienced staff to prevent, detect and correct anomalous events affecting the performance of the printed part. We address the complexity of this demanding task by designing a camera-based anomaly detection system utilizing probabilistic principal component analysis (PPCA). This is a machine learning technique is trained with thermal images collected during normal operation of the large-scale printer (Cincinnati BAAM). This technique is advantageous for practical applications as there is no need to artificially introduce anomalous conditions into model training. During deployment, we challenge this model by introducing deliberate variations of the extruder speed. We reduce extrusion speed to a lower level, between 70 and 95% of the nominal value to collected test images. Our results show that images are easily identified as anomalous for extruder speeds at or below 85% of the nominal speed, meaning that an anomalous reduction of the material deposition rate can be detected within seconds of its onset. We show that our results are robust to (a) camera-to-camera variability and (b) print-to-print variability.

Pike, John [ORNL]↗
DOE OSTI2024

Debiasing with Diffusion: Probabilistic Reconstruction of Dark Matter Fields from Galaxies with CAMELS

Abstract Galaxies are biased tracers of the underlying cosmic web, which is dominated by dark matter (DM) components that cannot be directly observed. Galaxy formation simulations can be used to study the relationship between DM density fields and galaxy distributions. However, this relationship can be sensitive to assumptions in cosmology and astrophysical processes embedded in galaxy formation models, which remain uncertain in many aspects. In this work, we develop a diffusion generative model to reconstruct DM fields from galaxies. The diffusion model is trained on the CAMELS simulation suite that contains thousands of state-of-the-art galaxy formation simulations with varying cosmological parameters and subgrid astrophysics. We demonstrate that the diffusion model can predict the unbiased posterior distribution of the underlying DM fields from the given stellar density fields while being able to marginalize over uncertainties in cosmological and astrophysical models. Interestingly, the model generalizes to simulation volumes ≈500 times larger than those it was trained on and across different galaxy formation models. The code for reproducing these results can be found athttps://github.com/victoriaono/variational-diffusion-cdm✎.

Astronomy & Astrophysics↗
DOE OSTI2025

Emulation With Uncertainty Quantification of Regional Sea‐Level Change Caused by the Antarctic Ice Sheet

Abstract Projecting regional sea‐level change under various climate‐change scenarios typically involves running forward simulations of the Earth's gravitational, rotational and deformational (GRD) response to ice‐mass change, which requires substantial computational cost if applied to probabilistic frameworks requiring thousands to millions of samples. Here we build emulators of regional sea‐level change at 27 coastal locations, due to the GRD effects associated with future Antarctic Ice Sheet mass change over the 21st century. The emulators are evaluated against a numerical sea‐level model applied to an ensemble of ice‐sheet model simulations of the Antarctic Ice Sheet through 2100. We build a physics‐based emulator using a recent sensitivity kernel approach and compare it to machine learning based emulators (neural network and conditional variational autoencoder methods). In order to quantify uncertainty, we derive well‐calibrated prediction intervals for regional sea‐level change via split‐conformal inference and linear regression, and show that Monte Carlo dropout does not yield well‐calibrated uncertainties in this instance. We also demonstrate substantial gains in computational efficiency using both the physics‐based emulator and neural networks in comparison to the numerical model for the complete regional sea‐level solution. Overall, we find the physics‐based emulator modestly outperforms the machine learning emulators for this problem.

58 GEOSCIENCES↗
DOE OSTI2025

Using the optimal combined index weight ratio to improve the probability of anomaly detection in big area additive manufacturing

Big Area Additive Manufacturing (BAAM) of composites requires significant time, energy, and material, so it is critical to reduce production inefficiencies to make functional parts without multiple iterations. Statistical process control coupled with Principal Component Analysis (PCA) is a powerful technique that provides a quick, computationally inexpensive, and intuitive way for operators to detect defects that form in a manufacturing process without massive datasets. Recently, a combined index that is a weighted sum of the Hotelling's T 2 and squared residual error statistics has been proposed that can be monitored in one chart, improving interpretation accuracy and simplicity. However, the literature does not offer a formal method to optimise the weights. Here, we introduce two new approaches to the traditional weight selection approach using simulated and BAAM image data. Approach 1 uses a theoretically motivated optimum inspired by probabilistic principal component analysis. Approach 2 systematically varies the ratio of the weights to find the optimum. We show that approach 1 delivers optimal anomaly detection performance in select cases while approach 2 fares better in practice. Surprisingly, we also show that choosing a more complex PCA model has a minimal negative impact on anomaly detection performance compared to a more simplistic model.

3-dimensional printing↗
DOE OSTI2024

Hector-FACTS Technical Report & User Guide: Integrating Hector into the Framework for Assessing Changes To Sea-level

The Framework for Assessing Changes To Sea-level (FACTS) platform was developed by (Kopp et al., 2023) as an open-source modular tool capable of generating probabilistic projections for global mean sea-level change and future relative and extreme sea-level change at New York City (Kopp et al., 2023). FACTS is the first open-source modular tool designed to explore deep uncertainty in SLR while also synthesizing across different modeling groups and integrating the various components of SLR used in key climate reports.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

GDSA framework, a computational framework for complex modeling problems in radioactive waste management

This paper details a computational framework to produce automated, graphical workflows, and how this framework can be deployed to support complex modeling problems like those in nuclear engineering. Key benefits of the framework include: automating previously manual workflows; intuitive construction and communication of workflows through a graphical interface; and automated file transfer and handling for workflows deployed across heterogeneous computing resources. This paper demonstrates the framework's application to probabilistic post-closure performance assessment of systems for deep geologic disposal of nuclear waste. However, the framework is a general capability that can help users running a variety of computational studies.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Evaluation of the 2022 West Nile virus forecasting challenge, USA

Abstract Background West Nile virus (WNV) is the most common cause of mosquito-borne disease in the continental USA, with an average of ~1200 severe, neuroinvasive cases reported annually from 2005 to 2021 (range 386–2873). Despite this burden, efforts to forecast WNV disease to inform public health measures to reduce disease incidence have had limited success. Here, we analyze forecasts submitted to the 2022 WNV Forecasting Challenge, a follow-up to the 2020 WNV Forecasting Challenge. Methods Forecasting teams submitted probabilistic forecasts of annual West Nile virus neuroinvasive disease (WNND) cases for each county in the continental USA for the 2022 WNV season. We assessed the skill of team-specific forecasts, baseline forecasts, and an ensemble created from team-specific forecasts. We then characterized the impact of model characteristics and county-specific contextual factors (e.g., population) on forecast skill. Results Ensemble forecasts for 2022 anticipated a season at or below median long-term WNND incidence for nearly all (> 99%) counties. More counties reported higher case numbers than anticipated by the ensemble forecast median, but national caseload (826) was well below the 10-year median (1386). Forecast skill was highest for the ensemble forecast, though the historical negative binomial baseline model and several team-submitted forecasts had similar forecast skill. Forecasts utilizing regression-based frameworks tended to have more skill than those that did not and models using climate, mosquito surveillance, demographic, or avian data had less skill than those that did not, potentially due to overfitting. County-contextual analysis showed strong relationships with the number of years that WNND had been reported and permutation entropy (historical variability). Evaluations based on weighted interval score and logarithmic scoring metrics produced similar results. Conclusions The relative success of the ensemble forecast, the best forecast for 2022, suggests potential gains in community ability to forecast WNV, an improvement from the 2020 Challenge. Similar to the previous challenge, however, our results indicate that skill was still limited with general underprediction despite a relative low incidence year. Potential opportunities for improvement include refining mechanistic approaches, integrating additional data sources, and considering different approaches for areas with and without previous cases. Graphical Abstract

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Feature-Based PMU Event Classification under Variable PMU Participation and Overlapping Events

Danovo Energy Solution's presented its paper named: Feature-Based PMU Event Classification under Variable PMU Participation and Overlapping Events at the 2026 Georgia Tech Fault & Disturbance Analysis Conference. The full paper can be found at OSTI ID# 3169150 Paper Abstract—Phasor Measurement Units (PMUs) stream time synchronized, high-resolution measurements from the grid, enabling data-driven techniques for event detection and classification. Accurate event classification improves grid reliability and stability. Events can be detected by varying numbers of PMUs and exhibit different durations depending on the event type. This variability challenges standard classifiers that require uniform input sizes. Moreover, multiple events may coincide, which increases classification complexity. Standard classifiers assign each instance to the class with the highest predicted probability, whereas overlapping events may exhibit comparable probabilities across multiple classes. In this study, to handle data size variability, we extract a wide range of time–frequency domain features from all available PMUs for each event into a fixed-length vector, facilitating the application of standard machine learning classifiers, including Random Forest, XGBoost, LightGBM, Support Vector Machine, and Multilayer Perceptron. To account for overlapping events, a probabilistic post-processing step is applied. For a given data instance, if multiple predicted class probabilities exceed 30% and the differences between them are less than 10%, the event is assigned to multiple classes. Experiments using real-world PMU data demonstrate that the Random Forest and XGBoost models achieve the highest accuracy, while the proposed post-processing method yields perfect classification performance on external unseen test sets.

Nematirad, Reza [Danova Energy Solutions]↗
DOE OSTI2026

Feature-Based PMU Event Classification under Variable PMU Participation and Overlapping Events

This paper is the basis for a presentation help at the 2026 Georgia Tech Fault & Disturbance Analysis Conference, which can be found at OSTI # 3168287 Paper Abstract—Phasor Measurement Units (PMUs) stream time synchronized, high-resolution measurements from the grid, enabling data-driven techniques for event detection and classification. Accurate event classification improves grid reliability and stability. Events can be detected by varying numbers of PMUs and exhibit different durations depending on the event type. This variability challenges standard classifiers that require uniform input sizes. Moreover, multiple events may coincide, which increases classification complexity. Standard classifiers assign each instance to the class with the highest predicted probability, whereas overlapping events may exhibit comparable probabilities across multiple classes. In this study, to handle data size variability, we extract a wide range of time–frequency domain features from all available PMUs for each event into a fixed-length vector, facilitating the application of standard machine learning classifiers, including Random Forest, XGBoost, LightGBM, Support Vector Machine, and Multilayer Perceptron. To account for overlapping events, a probabilistic post-processing step is applied. For a given data instance, if multiple predicted class probabilities exceed 30% and the differences between them are less than 10%, the event is assigned to multiple classes. Experiments using real-world PMU data demonstrate that the Random Forest and XGBoost models achieve the highest accuracy, while the proposed post-processing method yields perfect classification performance on external unseen test sets.

Nematirad, Reza [Danovo Energy Solutions]↗
DOE OSTI2026

Uncertainty quantification and reliability assessment for intermodal freight transportation

Intermodal freight optimization models support cost-effective, low-emission, and timely goods movement by coordinating trucks, rail, and barges. These models determine optimal flows, routing, and modal switches while respecting infrastructure and operational constraints. However, their real-world utility is often undermined by pervasive uncertainties-such as fluctuating transportation costs and emissions, variable terminal capacities, and uncertain freight demand-that distort key performance outcomes, including total system cost, carbon footprint, and transit time reliability. This study presents a structured framework for quantifying uncertainty in intermodal freight transportation (IFT) optimization. The framework evaluates how input uncertainty affects system performance and reliability, a critical need for ensuring that model-based decisions remain robust under real-world variability, especially amid volatile fuel prices, shifting demand, and growing disruptions. It integrates three complementary methods: (1) Sobol-based global sensitivity analysis to identify influential parameters affecting cost, emissions, and transit time, (2) Monte Carlo-based capacity perturbation analysis to assess robustness under probabilistic facility disruptions, and (3) Monte Carlo filtering with Bayesian inference to detect threshold-based performance vulnerabilities. The results highlight diesel truck unit cost as the dominant driver of variability. To improve system resilience, planners should prioritize uncertainty in fuel-related parameters when designing intermodal strategies.

Intermodal freight transportation↗
DOE OSTI2024

Radioisotope Identification with List-Mode Gamma Ray Data: A rigorous assessment on the value of temporal information applied to radioisotope identification.

This work explores the potential of utilizing temporal data from gamma-ray detectors, known as list-mode data, to enhance radioisotope identification. Traditional identification methods, which rely on full gamma-ray spectrum analysis, often require long dwell times and struggle with “confuser” sources, or spectra with similarly spaced spectral peaks. We hypothesize that by leveraging the probabilistic nature of nuclear decay and the time-encoded information from decay sequences and interactions with surrounding materials, we can improve classification accuracy over static spectral analysis. This research rigorously examines the temporal content of list-mode data through exploratory data analysis via correlation discovery and information theory. We further propose a basic classification model that can utilize spectral or temporal data (or both) to determine if the incorporation of temporal information can improve radioisotope identification. The findings suggest that the temporal information present in list-mode gamma-ray data has merit and should be further investigated.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Quantum subspace expansion in the presence of hardware noise

Finding ground state energies on current quantum processing units (QPUs) using algorithms such as the variational quantum eigensolver (VQE) continues to pose challenges. Hardware noise severely affects both the expressivity and trainability of parameterized quantum circuits, limiting them to shallow depths in practice. Here, we demonstrate that both issues can be addressed by synergistically integrating VQE with a quantum subspace expansion, allowing for an optimal balance between quantum and classical computing capabilities and costs. We perform a systematic benchmark analysis of the iterative quantum-assisted eigensolver in the presence of hardware noise. We determine ground state energies of 1D and 2D mixed-field Ising spin models on noisy simulators and the IBM QPUs ibmq_quito (5 qubits) and ibmq_guadalupe (16 qubits). To maximize accuracy, we propose a suitable criterion to select the subspace basis vectors according to the trace of the noisy overlap matrix. Finally, we show how to systematically approach the exact solution by performing controlled quantum error mitigation based on probabilistic error reduction on the noisy backend fake_guadalupe.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Revisiting a Drag Partition Model For Canopy-Like Roughness Elements

Turbulent flows over a large surface area (S) covered by n obstacles experience an overall drag due to the presence of the ground and the protruding obstacles into the flow. The drag partition between the roughness obstacles and the ground is analyzed using an analytical model proposed by Raupach (Boundary-Layer Meteorol 60:375-395, 1992) and is hereafter referred to as R92. The R92 is based on the premise that the wake behind an isolated roughness element can be described by a shelter area A and a shelter volume V. The individual sizes of A and V without any interference from other obstacles can be determined from scaling analysis for the spread of wakes. To upscale from an individual roughness element to n/S elements where wakes may interact, R92 adopted a background stress re-normalizing instead of reducing A or V with each element addition. This work demonstrates that R92’s approach results in a linear background stress reduction in A and V only when the ratio of n/S is small, due to a low probability of wake interactions. This probabilistic nature suggests that up-scaling from individual to multiple roughness elements can be re-formulated using stochastic averaging methods proposed here. The two approaches are shown to recover R92 under plausible conditions. An alternative scaling for the shelter volume is also proposed here using thermodynamic arguments of work and dissipation though the final outcome remains similar to R92. Comparisons between R92 and available data spanning more than two decades after R92 on blocks and vegetation-like roughness elements confirm the practical utility of R92. The agreement between R92 and this updated databases of experiments and simulations confirm the potential use of R92 in large-scale models provided that the relevant parameters accommodate certain features of the roughness element type (cube versus vegetation-like) and, to a lesser extent, their configuration throughout S. Last, a comparison between R92 and models based on first-order closure principles with constant mixing length suggests that R92 can outperform such models when evaluated across a wide range of roughness densities.

canopy turbulence↗
DOE OSTI2025

MOOSE ProbML: Parallelized probabilistic machine learning and uncertainty quantification for computational energy applications

Here, this paper presents the development and demonstration of massively parallel probabilistic machine learning (ML) and uncertainty quantification (UQ) capabilities within the Multiphysics Object-Oriented Simulation Environment (MOOSE), an open-source computational platform for parallel finite element and finite volume analyses. In addressing the computational expense and uncertainties inherent in complex multiphysics simulations, this paper integrates Gaussian process (GP) variants, active learning, Bayesian inverse UQ, adaptive forward UQ, Bayesian optimization, evolutionary optimization, and Markov chain Monte Carlo (MCMC) within MOOSE. It also elaborates on the interaction among key MOOSE systems — Sampler, MultiApp, Reporter, and Surrogate — in enabling these capabilities. The modularity offered by these systems enables development of a multitude of probabilistic ML and UQ algorithms in MOOSE. Example code demonstrations include parallel active learning and parallel Bayesian inference via active learning. The impact of these developments is illustrated through five applications relevant to computational energy applications: UQ of nuclear fuel fission product release, using parallel active learning Bayesian inference; very rare events analysis in nuclear microreactors using active learning; advanced manufacturing process modeling using multi-output GPs (MOGPs) and dimensionality reduction; fluid flow using deep GPs (DGPs); and tritium transport model parameter optimization for fusion energy, using batch Bayesian optimization. These capabilities are part of the MOOSE framework.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Artificial Intelligence and Machine Learning Support for Probabilistic Fracture Mechanics

In this research, artificial intelligence and machine learning (ML) methods are used to search an uncertain parameter space more efficiently for the most important inputs with respect to response sensitivities. These methods are applied to the Extremely Low Probability of Rupture (xLPR) probabilistic fracture mechanics code used at the U.S. Nuclear Regulatory Commission (NRC) in support of nuclear regulatory research. This report documents two separate but related sub-tasks: (1) ranking important uncertain input features with respect to target outputs, determined by convergence in confidence intervals for increasing sample sizes using simple random sampling; and (2) implementation of a reduced-order surrogate model for fast, approximate sample generation. Unoptimized readily available off-the-shelf ML models were used in both sub-tasks.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Solving high-dimensional inverse problems using amortized likelihood-free inference with noisy and incomplete data

Here, we present a likelihood-free probabilistic inversion method based on normalizing flows for high-dimensional inverse problems. The proposed method is composed of two complementary networks: a summary network for data compression and an inference network for parameter estimation. The summary network encodes raw observations into a fixed-size vector of summary features, while the inference network generates samples of the approximate posterior distribution of the model parameters based on these summary features. The posterior samples are produced in a deep generative fashion by sampling from a latent Gaussian distribution and passing these samples through an invertible transformation. We construct this invertible transformation by sequentially alternating conditional invertible neural network and conditional neural spline flow layers. The summary and inference networks are trained simultaneously. We apply the proposed method to an inversion problem in groundwater hydrology to estimate the posterior distribution of the log-conductivity field conditioned on spatially sparse time-series observations of the system’s hydraulic head responses. The conductivity field is represented with 706 degrees of freedom in the considered problem. Comparison with the likelihood-based iterative ensemble smoother PEST-IES method demonstrates that the proposed method accurately estimates the parameter posterior distribution and the observations’ predictive posterior distribution at a fraction of the inference time of PEST-IES.

conditional invertible neural network↗
DOE OSTI2025

Nonperturbative quantum gravity in a closed Lorentzian universe

We study how meaningful physical predictions can arise in nonperturbative quantum gravity in a closed Lorentzian universe. In such settings, recent developments suggest that the quantum gravitational Hilbert space is one-dimensional and real for each α-sector, as induced by spacetime wormholes. This appears to obstruct the conventional quantum-mechanical prescription of assigning probabilities via projection onto a basis of states. While previous approaches have introduced external observers or augmented the theory to resolve this issue, we argue that quantum gravity itself contains all the necessary ingredients to make physical predictions. We demonstrate that the emergence of classical observables and probabilistic outcomes can be understood as a consequence of partial observability: physical observers access only a subsystem of the universe. Tracing out the inaccessible degrees of freedom yields reduced density matrices that encode classical information, with uncertainties exponentially suppressed by the environment’s entropy. We develop this perspective using both the Lorentzian path integral and operator formalisms and support it with a simple microscopic model. Our results show that quantum gravity in a closed universe naturally gives rise to meaningful, robust predictions without recourse to external constructs.

AdS-CFT Correspondence↗
DOE OSTI2025

Huge ensembles – Part 1: Design of ensemble weather forecasts using spherical Fourier neural operators

Abstract. Simulating low-likelihood high-impact extreme weather events in a warming world is a significant and challenging task for current ensemble forecasting systems. While these systems presently use up to 100 members, larger ensembles could enrich the sampling of internal variability. They may capture the long tails associated with climate hazards better than traditional ensemble sizes. Due to computational constraints, it is infeasible to generate huge ensembles (comprised of 1000–10 000 members) with traditional, physics-based numerical models. In this two-part paper, we replace traditional numerical simulations with machine learning (ML) to generate hindcasts of huge ensembles. In Part 1, we construct an ensemble weather forecasting system based on spherical Fourier neural operators (SFNOs), and we discuss important design decisions for constructing such an ensemble. The ensemble represents model uncertainty through perturbed-parameter techniques, and it represents initial condition uncertainty through bred vectors, which sample the fastest-growing modes of the forecast. Using the European Centre for Medium-Range Weather Forecasts Integrated Forecasting System (IFS) as a baseline, we develop an evaluation pipeline composed of mean, spectral, and extreme diagnostics. With large-scale, distributed SFNOs with 1.1 billion learned parameters, we achieve calibrated probabilistic forecasts. As the trajectories of the individual members diverge, the ML ensemble mean spectra degrade with lead time, consistent with physical expectations. However, the individual ensemble members' spectra stay constant with lead time. Therefore, these members simulate realistic weather states during the rollout, and the ML ensemble passes a crucial spectral test in the literature. The IFS and ML ensembles have similar extreme forecast indices, and we show that the ML extreme weather forecasts are reliable and discriminating. These diagnostics ensure that the ensemble can reliably simulate the time evolution of the atmosphere, including low-likelihood high-impact extremes. In Part 2, we generate a huge ensemble initialized each day in summer 2023, and we characterize the simulations of extremes.

Mahesh, Ankur↗