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DOE OSTI2023

Modeling Ring Current Proton Fluxes Using Artificial Neural Network and Van Allen Probe Measurements

Abstract Terrestrial ring current dynamics are a critical part of the near‐space environment, in that they directly drive geomagnetic field variations that control particle drifts, and define geomagnetic storms. The present study aims to specify a global and time‐varying distribution of ring current proton using geomagnetic indices and solar wind parameters with their history as input. We train an artificial neural network (ANN) model to reproduce proton fluxes measured by the Radiation Belt Storm Probes Ion Composition Experiment instrument onboard Van Allen Probes. By choosing optimal feature parameters and their history length, the model results show a high correlation and a small error between model specifications and satellite measurements. The modeled results well capture energy‐dependent proton dynamics in association with geomagnetic storms, including inward radial diffusion, acceleration and decay. Our ANN model produces proton fluxes with their corresponding 3D spatiotemporal variations, capturing the latitudinal distribution and local time asymmetry that are consistent with observations and that can further inform theory.

Li, Jinxing↗

DOE OSTI2026

Advancing Industry 4.0: Multimodal Sensor Fusion for AI-Based Fault Detection in 3D Printing

Additive manufacturing, particularly fused deposition modeling, is transforming modern production by enabling rapid prototyping and complex part fabrication. However, its layer-by-layer process remains vulnerable to faults such as nozzle clogging, filament runout, and layer misalignment, which compromise print quality and reliability. Traditional inspection methods are costly, time-intensive, and often limited to post-process analysis, making them unsuitable for real-time intervention. In this current study, the authors developed a novel, low-cost, and portable faultdetection system that leverages multimodal sensor fusion and artificial intelligence for real-time monitoring in FDM-based 3D printing. The system integrates acoustic, vibration, and thermal sensing into a non-intrusive architecture, capturing complementary data streams that reflect both mechanical and process-related anomalies. Acoustic and thermal sensors operate in a fully contactless manner, while the vibration sensor requires minimal attachment such that it will not interfere with printer hardware, thereby preserving portability and ease of deployment. The multimodal signals are processed into spectrograms and time-frequency features, which are classified using convolutional neural networks for intelligent fault detection. The proposed system advances Industry 4.0 objectives by offering an affordable, scalable, and practical monitoring solution that improves faultdetection accuracy, reduces waste, and supports sustainable, adaptive manufacturing.

42 ENGINEERING↗

NASA NTRS2019

Design of Experiment for the Measurement of Aerosol Droplet Size Distribution of Temperature-Controlled Thermally Atomized Printed Electronic Inks

In-Space Manufacturing (ISM) centers around NASA’s growing need and ability to produce space technologies on demand in space. As the future of long term presence in space and deep space exploration approach, fundamental questions of our dependence on earth resupply to Low Earth Orbit (LEO) remain unanswered. ISM is leading various effort to evaluate the feasibility of producing essential spares and redundant parts on demand to enable a sustainable space-based supply chain model for part resupply. Among the parts and systems being considered, Avionics form the neural network of modern day aircraft and space vehicles providing a wealth of information ranging from Guidance, Navigation, and Control (GN&C) systems to on board Environmental Control and Life Support (ECLS) systems. Recent advances in the use of Aerosol Jet Technology to print Avionics components ranging from electrical traces on a circuit board to complex transistors and sensors raise the possibility of using such technology to reproduce or recreate electronic parts on demand with the help of custom electronics 3D printers. The challenge herein lies within the ability of such printers to generate and deposit an aerosol of electronic material utilizing processes independent of or enhanced by gravity to ensure controllably identical or improved behavior of the aerosol in an International Space Station (ISS) laboratory and on the ground. The behavior as well as the hazards and properties associated with such aerosols in a microgravity environment must be understood well in order to merit a feasible approach to utilizing them for manufacturing in space. In this report, we outline the experimental setup of a modified conventional vaping device to be used as the ideal gravity independent thermal atomization mechanism to generate aerosol. Our objective is to identify the ideal mass, density, and volume of our aerosolized droplets of ink to conclude that there exist a threshold of aerosolized ink droplet sizes that are indeed independent of the effects of gravity and remain stable after atomization. We use a Malvern Spraytec® Spray Particle Size Analyzer to perform real-time laser diffraction measurement of our ink droplets during atomization. The droplet size between conductive ink, dielectric ink and vegetable glycerin have been measured and contrasted. Furthermore, the mechanism of thermal atomization versus traditional pneumatic and ultrasonic atomization for operation in microgravity have been explored.

Wu, Chih-Hao↗

DOE OSTI2022

Adversarial methods to reduce simulation bias in neutrino interaction event filtering at liquid argon time projection chambers

For current and future neutrino oscillation experiments using large liquid argon time projection chambers (LAr-TPCs), a key challenge is identifying neutrino interactions from the pervading cosmic-ray background. Rejection of such background is often possible using traditional cut-based selections, but this typically requires the prior use of computationally expensive reconstruction algorithms. This work demonstrates an alternative approach of using a 3D submanifold sparse convolutional network trained on low-level information from the scintillation light signal of interactions inside LAr-TPCs. This technique is applied to example simulations from ICARUS, the far detector of the short baseline neutrino program at Fermilab. The results of the network, show that cosmic background is reduced by up to 76.3% whilst neutrino interaction selection efficiency remains over 98.9%. We further present a way to mitigate potential biases from imperfect input simulations by applying domain adversarial neural networks (DANNs), for which modified simulated samples are introduced to imitate real data and a small portion of them are used for adversarial training. A series of mock-data studies are performed and demonstrate the effectiveness of using DANNs to mitigate biases, showing neutrino interaction selection efficiency performances significantly better than that achieved without the adversarial training.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

NASA NTRS1989

Use of 3D vision for fine robot motion

An integration of 3-D vision systems with robot manipulators will allow robots to operate in a poorly structured environment by visually locating targets and obstacles. However, by using computer vision for objects acquisition makes the problem of overall system calibration even more difficult. Indeed, in a CAD based manipulation a control architecture has to find an accurate mapping between the 3-D Euclidean work space and a robot configuration space (joint angles). If a stereo vision is involved, then one needs to map a pair of 2-D video images directly into the robot configuration space. Neural Network approach aside, a common solution to this problem is to calibrate vision and manipulator independently, and then tie them via common mapping into the task space. In other words, both vision and robot refer to some common Absolute Euclidean Coordinate Frame via their individual mappings. This approach has two major difficulties. First a vision system has to be calibrated over the total work space. And second, the absolute frame, which is usually quite arbitrary, has to be the same with a high degree of precision for both robot and vision subsystem calibrations. The use of computer vision to allow robust fine motion manipulation in a poorly structured world which is currently in progress is described along with the preliminary results and encountered problems.

Lokshin, Anatole↗

DOE OSTI2020

Vision-Guided Automation and Assistance

Robotic automation and assistance is an excellent way to increase efficiency and safety when working in a potentially hazardous workspace. However, many traditional automation approaches rely on the precise placement of items to be manipulated. The scope of such automated tasks is also limited to the manipulation of one type of object since there is no way to distinguish between different objects. The addition of a vision pipeline, where robot vision is used to localize and recognize objects, can allow the robot to perform more complex tasks in a variable workspace. In my vision pipeline, a depth camera is used to generate a 3D point cloud of the workspace. Objects to be manipulated are isolated in the point cloud by filtering out shared surfaces and using Euclidean cluster extraction to group clusters of points. The locations of the objects are then estimated from the point cloud of the isolated objects. The localization of objects with robot vision allows for variable workspaces, reducing the overhead associated with requiring all objects to be precisely placed in the workspace. For object recognition, deep learning is used to train a neural network that classifies objects from the raw point clouds. More complex tasks that require multiple objects to be manipulated differently can be achieved through the vision pipeline. Through its ability to visualize the workspace, robot vision greatly improves efficiency and safety of automated and assistive tasks.

42 ENGINEERING↗

NASA NTRS2023

EVA Task and 3D Pose Recognition from Video

Extravehicular Activity (EVA) has been known to involve potential risks of biomechanical stresses and injuries to crewmembers. Gathering of EVA motion patterns is necessary for risk analysis and mitigation. However, many existing techniques, such as motion capture systems, are not only cost-prohibitive but are impractical for retrospective analysis of past missions. In this work, a software tool was developed, which can estimate the 3D poses of a spacesuit from photographs or videos, without using special sensors or equipment. The tool is based on the state-of-the-art artificial intelligence and machine learning (AI/ML) system, which was trained by studying and capturing motion patterns of past and current spacesuit test data. The AI/ML tool was further enhanced using synthetically generated data, in which the suit postures, backgrounds, camera angles and illumination conditions were parametrically adjusted and rendered for training. The tool, incorporated the methodologies of Convolutional Neural Network (CNN), was trained, and tested in the cloud computing environment. The trained model was then applied on new imagery and video to extract estimated joint positions and suit outlines. The joint positions were further processed to capture activity (“digging”), pose labels (“bending”), and other useful downstream information. The model performance on new imagery and video was successfully assessed for accuracy and reliability. This AI/ML based posture recognition tool thus allows for the quantification of injury risk and task performance characterization for both current and past missions and training, which can immensely help to improve EVA task and suit design.

Kyung Han Kim↗

DOE OSTI2022

Real-time deep-learning inversion of seismic full waveform data for CO 2 saturation and uncertainty in geological carbon storage monitoring

Deep-learning inversion has recently drawn attention in geological carbon storage research due to its potential of imaging and monitoring carbon storage in real time, significantly improving efficiency and safety of carbon storage operations. We present a deep-learning full waveform inversion method that after the neural network has been trained can image CO 2 saturation and its uncertainty in real time. Our deep-learning inversion method is based on the U-Net architecture with the neural network trained on pairs of synthetic seismic data and CO 2 saturation models. Accordingly, our training establishes a mapping relationship between seismic data and CO 2 saturation models and once fully trained directly estimates CO 2 saturation as a function of subsurface location. We further quantify uncertainties of CO 2 saturation estimates using the Monte Carlo dropout method and a bootstrap aggregating method. For this proof-of-concept study, the CO 2 training models and data are derived from the Kimberlina 1.2 model, a hypothetical 3D geological carbon storage model that is constructed based on various geological and hydrological data from the Southern San Joaquin Basin, California. We perform deep-learning inversion experiments using noise-free and noisy training and test data sets and compare the results. Our modelling experiments show that (1) the deep-learning inversion can estimate 2D distributions of CO 2 fairly well even in the presence of Gaussian random noise and (2) both CO 2 saturation imaging and uncertainty quantification can be done in real time. Our results suggest that the deep-learning inversion method can serve as a robust real-time monitoring tool for geological carbon storage and/or other time-varying reservoir/aquifer properties that result from injection, extraction, and/or other subsurface transport phenomena.

58 GEOSCIENCES↗

DOE OSTI2023

Time-lapse VSP integration and calibration of subsurface stress field utilizing machine learning approaches: A case study of the morrow B formation, FWU

This study aims to develop a methodology for calibrating subsurface stress changes through time-lapse vertical seismic profiling (VSP) integration. The selected study site is a region around the injector well located within Farnsworth field unit (FWU), where there is an ongoing CO 2 -enhanced oil recovery (EOR) operation. In our study, a site-specific rock physics model was created from extensive geological, geophysical, and geomechanical characterization through 3D seismic data, well logs, and core assessed as part of the 1D MEM conducted on the characterization well within the study area. Here, the Biot-Gassmann workflow was utilized to combine the rock physics and reservoir simulation outputs to determine the seismic velocity change due to fluid substitution. Modeled seismic velocities attributed to mean effective stress were determined from the geomechanical simulation outputs, and the stress-velocity relationship developed from ultrasonic seismic velocity measurements. A machine learning-assisted workflow comprised of an artificial neural network and a particle swarm optimizer (PSO) was utilized to minimize a penalty function created between the modeled seismic velocities and the observed time-lapse VSP dataset. The successful execution of this workflow has affirmed the suitability of acoustic time-lapse measurements for 4D-VSP geomechanical stress calibration pending measurable stress sensitivities within the anticipated effective stress changes and the availability of suitable and reliable datasets for petroelastic modeling. © 2023 Society of Chemical Industry and John Wiley & Sons, Ltd.

58 GEOSCIENCES↗

DOE OSTI2024

Three-dimensional reconstruction of laser-direct-drive inertial confinement fusion hot-spot plasma from x-ray diagnostics on the OMEGA laser facility (invited)

A deep-learning convolutional neural network (CNN) is used to infer, from x-ray images along multiple lines of sight, the low-mode shape of the hot-spot emission of deuterium–tritium (DT) laser-direct-drive cryogenic implosions on OMEGA. The motivation of this approach is to develop a physics-informed 3-D reconstruction technique that can be performed within minutes to facilitate the use of the results to inform changes to the initial target and laser conditions for the subsequent implosion. The CNN is trained on a 3D radiation-hydrodynamic simulation database to relate 2D x-ray images to 3D emissivity at stagnation. The CNN accounts for the lack of an absolute spatial reference and the different bands of photon energies in the x-ray images. While previous works studied the effect of mode-1 asymmetries on implosion performance using nuclear diagnostics, this work focuses on the effect of mode 2 inferred from x-ray diagnostics on implosion performance. A current analysis of 19 DT cryogenic implosions indicates there is an upper limit of ~20% reduction in the neutron yield caused by an ℓ = 2 amplitude for ℓ 2 /ℓ 0 ≤ 0.32. Here, these conclusions are supported by 2D simulations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Learning diffractive optical communication around arbitrary opaque occlusions

Abstract Free-space optical communication becomes challenging when an occlusion blocks the light path. Here, we demonstrate a direct communication scheme, passing optical information around a fully opaque, arbitrarily shaped occlusion that partially or entirely occludes the transmitter’s field-of-view. In this scheme, an electronic neural network encoder and a passive, all-optical diffractive network-based decoder are jointly trained using deep learning to transfer the optical information of interest around the opaque occlusion of an arbitrary shape. Following its training, the encoder-decoder pair can communicate any arbitrary optical information around opaque occlusions, where the information decoding occurs at the speed of light propagation through passive light-matter interactions, with resilience against various unknown changes in the occlusion shape and size. We also validate this framework experimentally in the terahertz spectrum using a 3D-printed diffractive decoder. Scalable for operation in any wavelength regime, this scheme could be particularly useful in emerging high data-rate free-space communication systems.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Design of flexible proton beam imaging energy spectrometers (PROBIES)

A simple repeating step-filtered structure has been designed and deployed for the detection of MeV-energy proton beams produced from high-intensity short-pulse laser-driven experiments. Due to the diagnostic's ability to recover energy-resolved images of proton beams, it is called the proton beam imager and energy spectrometer (or PROBIES). The flexible design has two useful applications. First, it can be fielded in a configuration with a scintillator and imaging setup in order to collect proton beam information in high-repetition rate experiments. Here we show a configuration that collects the equivalent of a nine-film radiochromic film (RCF) stack, and a technique for using a neural network (NN) to rapidly analyze the images on millisecond time-scales. Second, when using RCF stacks as the detector, the energy resolution capability is greatly increased compared to traditional RCF stacks, while simultaneously reducing the total number of films required to make each measurement. We demonstrate a configuration that provides up to 90 spatially- and energy-resolved datapoints using just ten films. Both designs presented here can be easily customized for anticipated experimental outputs and manufactured at low cost. Such designs allow for rapid prototyping using modern high-accuracy 3D printers or on-demand computer numerical control machining to reduce the reliance on time-consuming film media, analysis, or bulky electro-magnetically dispersing spectrometers. The analysis of data is discussed and a methodology for constructing a NN that is capable of rapidly analyzing data on-the-fly with greater than 95% accuracy is presented.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Fast meta-solvers for 3D complex-shape scatterers using neural operators trained on a non-scattering problem

Three-dimensional target identification using scattering techniques requires high accuracy solutions and very fast computations for real-time predictions in some critical applications. We first train a deep neural operator (DeepONet) to solve wave propagation problems described by the Helmholtz equation in a domain without scatterers but at different wavenumbers and with a complex absorbing boundary condition. We then design two classes of fast meta-solvers by combining DeepONet with either relaxation methods, such as Jacobi and Gauss-Seidel, or with Krylov methods, such as GMRES and BiCGStab, using the trunk basis of DeepONet as a coarse-scale preconditioner. We leverage the spectral bias of neural networks to account for the lower part of the spectrum in the error distribution while the upper part is handled inexpensively using relaxation methods or fine-scale preconditioners. The meta-solvers are then applied to solve scattering problems with different shape of scatterers, at no extra training cost. We first demonstrate that the resulting meta-solvers are shape-agnostic, fast, and robust, whereas the standard standalone solvers may even fail to converge without the DeepONet. We then apply both classes of meta-solvers to scattering from a submarine, a complex three-dimensional problem. We achieve very fast solutions, especially with the DeepONet-Krylov methods, which require orders of magnitude fewer iterations than any of the standalone solvers.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Online thermal profile prediction for large format additive manufacturing: A hybrid CNN-LSTM based approach

Large format additive manufacturing (LFAM) is an advanced 3D printing technique that efficiently fabricates large-scale components through a layer-by-layer extrusion and deposition process. Accurate surface layer temperature monitoring is essential to prevent manufacturing failures and ensure final product quality. Traditional physics-based offline approaches for simulating thermal behavior are often inefficient and complex, posing challenges on real-time, in-situ monitoring. Here, to address this, we propose a data-driven hybrid CNN-LSTM model to predict sequential thermal images of arbitrary length using real-time infrared thermal imaging. In this approach, a Convolutional Neural Networks (CNN) is trained offline to capture spatial features, reduce dimensional complexity, and enhance time efficiency, while a stacked Long Short-Term Memory (LSTM) is applied online to capture temporal information for improved prediction of future thermal behavior in subsequent printing layers. Model performance is evaluated using MSE, SSIM, and PSNR metrics and is benchmarked against stacked LSTM and convolutional LSTM models, demonstrating superior accuracy and applicability. Additionally, to mitigate noise from moving extruders and gantry backgrounds in thermal images, a fine-tuned semantic segmentation model is implemented offline to extract printing geometry, enabling precise temperature tracking along the tool path for further thermal analysis. The frameworks developed in this study significantly advance temperature monitoring, thermal analysis, and in-situ manufacturing control for LFAM, bridging the gap between theoretical modeling and practical application.

Geometry extraction↗

DOE OSTI2026

Predicting the single-site and multi-site event discrimination power of dual-phase time projection chambers

Dual-phase xenon time projection chambers (TPCs) are widely used in searches for rare dark matter and neutrino interactions, in part because of their excellent position reconstruction capability in 3D. Despite their millimeter-scale resolution along the charge drift axis, xenon TPCs face challenges in resolving single-site (SS) and multi-site (MS) interactions in the transverse plane. In this paper, we build a generic TPC model with an idealized signal readout, and use Fisher Information (FI) to predict its theoretical capability of differentiating SS and MS events using the electroluminescence signal. We also demonstrate via simulation that, when only statistical photon noise is present, the theoretical limits can be approached with conventional reconstruction algorithms like maximum likelihood estimation, and with a convolutional neural network classifier. The implications of this study on future TPC experiments will be discussed.

Physics↗

NASA NTRSDate not supplied

Towards Physics Guided Optical Flow for Tracking Atmospheric Motion

Observations of atmospheric 3D winds are critical for improving short-range and long-range forecasting. Such advancement in forecasting directly applies to research in a number of areas including convective processes, wildfire plumes and tornado prediction. Atmospheric Motion Vectors (AMVs) provide a passively sensed approach to quantifying horizontal motion and cloud heights, which are typically sourced from geostationary sensors due to the availability of high frequency observations. Recent work has shown that estimating AMVs by tracking individual pixels with dense optical flow is a promising new direction. In this work, we compare state-of-the-art convolutional neural networks for optical flow in a physics-guided deep learning framework for predicting AMVs. The approach is semi-supervised and uses physically informed wind vectors from high-resolution numerical simulations for supervised learning followed by fine-tuning though warping and reconstruction of full-disk geostationary images (GOES-16). In the vertical direction, we use labels from the CALIPSO low-earth orbit satellite to predict cloud height from 16-band geostationary images with a neural network. We present results for both tasks on held-out time periods and secondary datasets.

Geostationary↗

DOE OSTI2023

Iterative multi-task learning and inference from seismic images

Seismic interpretation aims to extract quantitative and interpretable attributes from a seismic image produced using some migration method to inform characteristics of a subsurface reservoir or target of interest. Current paradigms for computing seismic attributes mostly rely on single-task algorithms. We develop an iterative, multi-task machine learning method to learn and infer multiple attributes from a seismic image. This method is composed of two stages: a multi-task inference stage and a multi-modal, multi-task refinement stage. The basic mechanism of this method is that we train a multi-task inference neural network (NN) to estimate a set of attributes, including a relative geological time (RGT), a denoised higher-resolution (DHR) seismic image, and multiple fault attributes (including probability, dip, and strike), from a low-resolution, noisy seismic image; then we input the inferred attributes to a multi-task refinement NN to enhance the raw inference results iteratively. The two multi-task NNs are trained separately based on synthetic seismic images and associated attributes generated by a geological modeling algorithm. The software we intend to release is a PyTorch implementation of this multi-task learning method for both 2D and 3D cases along with scripts to run the training/validation. The algorithm and software can be a useful tool for automatic seismic interpretation.

Gao, Kai↗

NASA NTRSDate not supplied

Towards Physics Guided Optical Flow for Tracking Atmospheric Motion

Atmospheric 3D winds in the horizontal and vertical directions are critical for improving short-range and long-range forecasting. Such advancement in forecasting directly applies to research in a number of areas including convective processes, wildfire plumes and tornado prediction. Atmospheric Motion Vectors (AMVs) provide a passively sensed approach to quantifying horizontal motion and cloud heights, which are typically sourced from geostationary sensors due to the availability of high frequency observations. Recent work has shown that estimating AMVs by tracking individual pixels with dense optical flow is a promising new direction. In this work, we use a state-of-the-art convolutional neural network for optical flow (FlowNetS) in a physics-guided deep learning framework for predicting AMVs in the horizontal direction. The approach is semi-supervised and uses physically informed wind vectors from high-resolution numerical simulations (DYAMOND) for supervised learning followed by fine-tuning though warping and reconstruction of full-disk geostationary images (GOES-16). In the vertical direction, we use labels from the CALIPSO low-earth orbit satellite to predict cloud height from 16-band geostationary images with a neural network. We present results for both tasks on held-out time periods and secondary datasets.

geostationary↗