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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 OSTI2026

3D probabilistic fracture mechanics / computational fluid dynamics simulation of a reactor pressure vessel under transient conditions

Reactor pressure vessels (RPVs) are safety-critical light-water-reactor components that, under irradiation, experience long-term material degradation in the form of embrittlement. This can increase their susceptibility to fracture under thermal-shock conditions, which could occur during off-normal transients such as loss-of-coolant accidents (LOCAs). During a LOCA, the most severe conditions for the RPV occur when emergency core cooling water is injected through the cold legs into the water-and-steam-filled RPV. The rapid cooling of the downcomer and internal RPV surface causes decreased temperature and elevated thermally driven tensile stresses in the RPV wall. This, combined with long-term material embrittlement, may cause fracture initiation at pre-existing flaws, challenging the integrity of the RPV. Assessing RPV integrity during transients with a large spatial variation in the coolant temperature requires a modeling approach that considers the effects of spatially varying coolant temperature on the fracture probability of a population of flaws distributed throughout the RPV, accounting for spatially varying embrittlement. Here, the present study addresses this need by demonstrating first-of-its-kind coupling of a high-fidelity 3D computational fluid dynamics code with 3D probabilistic fracture mechanics This was accomplished using representative models of a pressurized-water reactor subjected to small- and medium-break LOCA conditions, both of which can result in large spatial temperature variations. While the observed impact of accounting for 3D effects was minimal under the small-break LOCA this study indicates a significant increase in the probability of fracture initiation under the medium-break LOCA when 3D effects are considered, relative to a spatially uniform cooling scenario.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Deep probabilistic direction prediction in 3D with applications to directional dark matter detectors

Abstract We present the first method to probabilistically predict 3D direction in a deep neural network model. The probabilistic predictions are modeled as a heteroscedastic von Mises-Fisher distribution on the sphere S 2 , giving a simple way to quantify aleatoric uncertainty. This approach generalizes the cosine distance loss which is a special case of our loss function when the uncertainty is assumed to be uniform across samples. We develop approximations required to make the likelihood function and gradient calculations stable. The method is applied to the task of predicting the 3D directions of electrons, the most complex signal in a class of experimental particle physics detectors designed to demonstrate the particle nature of dark matter and study solar neutrinos. Using simulated Monte Carlo data, the initial direction of recoiling electrons is inferred from their tortuous trajectories, as captured by the 3D detectors. For 40 keV electrons in a 70% He 30% CO 2 gas mixture at STP, the new approach achieves a mean cosine distance of 0.104 (26 ∘ ) compared to 0.556 (64 ∘ ) achieved by a non-machine learning algorithm. We show that the model is well-calibrated and accuracy can be increased further by removing samples with high predicted uncertainty. This advancement in probabilistic 3D directional learning could increase the sensitivity of directional dark matter detectors.

Computer Science↗

DOE OSTI2025

Evaluating FRI3D for Cost Savings in Fire Hazard Analysis at DOE Sites

A fire hazard analysis, required for many U.S. Department of Energy (DOE) facilities, is a complex, cumbersome, and costly process. Fire hazard analyses may be viewed as a checkbox, but ideally and in spirit with the DOE-STD-1066, the fire hazard analysis (FHA) should be a part of the workflow and used to help in modifications, maintenance, and improving operational safety. With current FHA development processes, it is both time and cost prohibitive for true integration. A tool called Fire Risk Investigation in 3D or FRI3D was developed under the DOE Light Water Reactor Sustainability program to simplify and automate many aspects of a fire probabilistic risk analysis for existing nuclear power plants. The FRI3D tool automates fire scenarios by combining approved fire simulation codes, U.S. Nuclear Regulatory Commission fire calculations methods, 3D modeling and visualization, and probabilistic risk analysis models into a single workflow supported with a user interface. FRI3D was initially designed for used in combination with a PRA, this case study, evaluated using FRI3D for a plant modification, determined the benefits that detailed fire modeling can have for U.S. Department of Energy facilities with or without a PRA model. It also looked at what tasks from DOE requirements could be reduced using the tool and what is needed to integrate fire hazard analysis into site workflow.

97 - MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Probabilistic flux limiters

The stable numerical integration of shocks in compressible flow simulations relies on the reduction or elimination of Gibbs phenomena (unstable, spurious oscillations). A popular method to virtually eliminate Gibbs oscillations caused by numerical discretization in under-resolved simulations is to use a flux limiter. A wide range of flux limiters have been studied in the literature, with recent interest in their optimization via machine learning methods trained on high-resolution datasets. The common use of flux limiters in numerical codes as plug-and-play blackbox components makes them key targets for design improvement. Even for deterministic dynamical models, numerical uncertainty is introduced via coarse-graining required by insufficient computational power to solve all scales of motion. Conventional flux limiters are deterministic and lack the capacity to address uncertainties, both aleatoric (inherent randomness) and epistemic (modeling uncertainty due to limited knowledge), which arise in coarse-grained numerical simulations. Here, we introduce a conceptually distinct type of flux limiter that is designed to handle the effects of randomness in the model and uncertainty in model parameters. Unlike traditional single-function flux limiters, these new probabilistic flux limiters incorporate multiple flux limiting functions, each applied with a learned probability drawn from high-resolution data to mitigate the effects of uncertainty in numerical simulations. This approach departs from traditional single-function limiters by explicitly modeling and incorporating uncertainty into the shock capturing process. Using the example of Burgers' equation as a testbed, we show that a machine learned, probabilistic flux limiter may be used in a shock capturing code to more accurately capture shock profiles. In particular, we show that our probabilistic flux limiter outperforms standard limiters and can be successively improved upon (up to a point) by expanding the set of probabilistically chosen flux limiting functions.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

Neutrino-Argon Cross Sections in MicroBooNE: Measurements Spanning Multiple Interaction Channels, Final States, and Neutrino Fluxes

Neutrinos are one of the most elusive particles in the Standard Model of particle physics due to their tiny interaction cross section, which makes them challenging to detect and study. There are three known flavors of neutrinos, and any given neutrino probabilistically oscillates between them as a function of the particle's energy and propagation distance. Experimental characterization of these oscillations elucidates fundamental properties of the neutrino and the Standard Model. Meeting the precision goals of ongoing and future oscillation measurements requires detailed modeling of the way neutrinos interact with nuclear matter. Precision modeling of these interactions is a challenging theoretical problem, rich with intricate physics effects to explore, and requires input from equally precise measurements of neutrino-nucleus interaction cross sections spanning a broad range of scattering channels. To fill this need, there is an ongoing multi-experiment effort to measure these cross sections across energies, interaction channels, and nuclear targets. This thesis describes three analyses reporting neutrino-argon cross section measurements with data from the MicroBooNE liquid argon time projection chamber detector. These span multiple interaction channels, final state topologies, and neutrino fluxes. The first analysis is a set of inclusive charged current muon neutrino cross section measurements for final states with and without protons, which provides a unique view of the hadronic final state produced in these interactions. Second is a set of cross section measurements for neutral current neutral pion production, which provides a vital dataset on this under-characterized channel. Third is significant progress on measuring neutrinos produced by kaons decaying at rest, which represents a unique opportunity to measure cross sections with a mono-energetic flux of neutrinos. These measurements are accompanied by a modeling study in the GiBUU theory framework, which probes the sensitivity of the muon neutrino and pion production measurements to the modeling of nucleon-nucleon final state interactions in neutrino-nucleus scattering.

Bogart, Benjamin [Michigan U.]↗

DOE OSTI2026

Faster Randomized Dynamical Decoupling

We present a randomized dynamical decoupling (DD) protocol that can substantially improve the performance of any given deterministic DD scheme for suppressing coherent noise by using no more than two additional pulses. Our construction is implemented by probabilistically applying sequences of pulses, which, when combined, effectively eliminate the error terms that scale linearly with the system-environment coupling strength. As a result, we show that a randomized protocol using a few pulses can outperform deterministic DD protocols that require considerably more pulses. Furthermore, we prove that the randomized protocol provides an improvement compared to deterministic DD sequences that aim to reduce the error in the system’s Hilbert space, such as Uhrig DD, which had been previously regarded to be optimal. To rigorously evaluate the performance, we introduce new analytical methods suitable for analyzing higher-order DD protocols that might be of independent interest. Here, we also present numerical simulations confirming the significant advantage of using randomized protocols compared to widely used deterministic protocols.

Quantum algorithms & computation↗

DOE OSTI2026

Neural Posterior Estimation for Scalable and Accurate Inverse Parameter Inference in Li-Ion Batteries

Diagnosing the internal state of Li-ion batteries is critical for battery research, operation of real-world systems, and prognostic evaluation of remaining lifetime. By using physics-based models to perform probabilistic parameter estimation via Bayesian calibration, diagnostics can account for the uncertainty due to model fitness, data noise, and the observability of any given parameter. However, Bayesian calibration in Li-ion batteries using electrochemical data is computationally intensive even when using a fast surrogate in place of physics-based models, requiring many thousands of model evaluations. A fully amortized alternative is neural posterior estimation (NPE). NPE shifts the computational burden from the parameter estimation step to data generation and model training, reducing the parameter estimation time from minutes to milliseconds, enabling real-time applications. The present work shows that NPE can infer parameters equally or more accurately than Bayesian calibration, even if it leads to higher voltage reconstruction errors. We also demonstrate that the higher computational costs for data generation are tractable even in high-dimensional cases (ranging from 6 to 27 estimated parameters). The NPE method also offers several interpretability advantages over Bayesian calibration, such as local parameter sensitivity to specific regions of the voltage curve. The NPE method is demonstrated using an experimental fast charge dataset, with parameter estimates validated against measurements of loss of lithium inventory and loss of active material. The implementation is made available in a companion repository (https://github.com/NatLabRockies/BatFIT).

25 ENERGY STORAGE↗

DOE OSTI2025

Power System Feature-Based Event Classification by Means of Multiple PMU Data

Abstract—Phasor Measurement Units (PMUs) provide time synchronized measurements across the power grid, enabling data driven event detection and classification for enhanced system monitoring and situational awareness. However, variations in event duration, spatial extent, and severity, along with coincident events, pose challenges for conventional classification models that require fixed-size inputs. This paper presents a feature-based framework that aggregates diverse attributes from all available PMUs for each event into a fixed-length vector, facilitating the application of standard machine learning classifiers, including Random Forest, XGBoost, and Multilayer Perceptron. A probabilistic post-processing scheme is further introduced to enable multi-label classification in the presence of overlapping events. Experiments using real-world PMU data demonstrate that the Random Forest model achieves 95% accuracy, while the proposed post-processing method yields an additional 3% improvement.

Nematirad, Reza↗

DOE OSTI2024

Probabilistic Seismic Hazard Assessment for Azerbaijan

Probabilistic Seismic Hazard Assessments (PSHA) underpin the determination of seismic loads in most contemporary seismic provisions of building codes around the world. Modern building codes are migrating towards using the entire uniform hazard spectrum at a range of vibration periods (typically up to 4 s or 10 s) rather than a single peak value such as peak ground acceleration (PGA), thus requiring a larger range of PSHA outputs. The hazard maps in the current version of the building code of Azerbaijan (2011) are in terms of intensity and peak ground acceleration. Recognizing the need for an up-to-date seismic hazard assessment in the country, Seismic Cooperation Program (SCP) under the Lawrence Livermore National Laboratory (LLNL) undertook, in coordination with the Republican Seismic Survey Center of the Azerbaijan National Academy of Sciences and the Azerbaijan Scientific Research Institute of Construction and Architecture, a PSHA study that reflects new seismic data recorded locally and recent research conducted nationally and regionally since the last update to the building code. The PSHA framework for this project was designed to help develop a new earthquake catalogue, to incorporate a novel characterization of ground motions that specifically reflects the attenuation characteristics in the eastern Caucasus, and to generate hazard information in a form that is useful for an update of the current building code or the development of a new building code for Azerbaijan. The project also aimed to provide training and support for the local seismologists and engineers related to the seismic hazard models, probabilistic seismic hazard results and their use towards changes in the building code.

58 GEOSCIENCES↗

DOE OSTI2025

Deriving the Landauer Principle From the Quantum Shannon Entropy

We derive an expression to determine the equilibrium probability distribution of a quantum state in contact with a noisy thermal environment that formally separates contributions from quantum and classical forms of probabilistic uncertainty. A statistical mechanical interpretation of this probability distribution enables us to derive an expression for the minimum free energy costs for arbitrary (reversible or irreversible) quantum state changes. In conclusion, based on this derivation, we demonstrate that–in contrast to classical systems–the free energy required to erase or reset a qubit depends sensitively on both the fidelity of the target state and on the physical properties of the environment, such as the number of quantum bath states, due primarily to the entropic effects of system-bath entanglement.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

A systematic decision-making methodology to formalize the selection of degree of realism in screening analysis of probabilistic risk assessment

In the nuclear power domain, Probabilistic Risk Assessment (PRA) is used to inform decision-making for Nuclear Power Plants (NPPs). Recently, there has been an increase in the utilization of modeling and simulation (M&S) to support the estimation of PRA inputs. Risk analysts should carefully select the PRA items that require M&S and their degree of realism (DoR) with consideration of the required resources. To support this selection, this article formulates a systematic decision-making approach for the DoR selection. The DoR selection is made based on two predictive decision-making attributes: the predicted differences in safety risk estimate (ΔSaRi) and the cost of analysis (ΔCAN). This research also develops and quantifies causal models to estimate ΔSaRi and ΔCAN. The causal model-based prediction of ΔSaRi and ΔCAN helps reduce the trial-and-error nature of the DoR selection in the PRA screening analysis and provides insights for DoR selection and the gradual refinements of PRA realism. This approach is demonstrated for a case study on fire PRA of NPPs, where an adequate DoR is selected from two fire models: an engineering correlation and a zone model.

Alkhatib, Sari [Department of Nuclear, Plasma, and↗

DOE OSTI2026

D$e^+e^-$ffusion: Capturing the Beam-Beam Physics of $e^+e^-$ Collisions with Diffusion Models

Beam-induced backgrounds at high-luminosity $e^+e^-$ colliders, such as the FCC-ee, are dominated by incoherent pair creation (IPC), and require computationally expensive simulations with dedicated Monte Carlo (MC) event generators. Reliable detector and machine-detector interface studies necessitate event samples that are several orders of magnitude larger than what is practically attainable with existing MC. To alleviate this bottleneck, we present D$e^+e^-$ffusion, a denoising diffusion probabilistic model that operates as a permutation-equivariant, set-valued surrogate for fast IPC simulation. Trained on a small GuineaPig++ sample, D$e^+e^-$ffusion faithfully reproduces the marginal and joint kinematic, angular, and positional distributions of all three IPC production processes. In addition, we assess the fidelity at the detector level by propagating both Geant4 and D$e^+e^-$ffusion events through a Geant4 simulation of the CLD vertex detector and by training a transformer-based two-sample classifier; the classifier achieves an area under the ROC curve of $0.553 \pm 0.016$. The trained model generates events nearly four orders of magnitude faster than Geant4, paving the way for a fast-simulation surrogate for FCC-ee design studies.

Chahine, Antonio [Imperial Coll., London]↗

DOE OSTI2024

The Essence of Cryptol: A Denotational Cryptol Interpreter in Coq for Foundational Assurances for Quantum Resistant Cryptosystems

Systems of the utmost consequence need a means to establish authenticity of software and data. Cryptosystems implement authentication, but can be vulnerable to cryptographic and implementation attacks. With the threat of quantum cryptographic attacks, “post-quantum” cryptosystems (PQCs) must be henceforth used in these systems. However, the new cryptography needs new ways to, rigorously and machine-checkably, prove systems free of vulnerabilities. We propose a retargetable capability to rapidly instantiate proven correct postquantum cryptosystems through novel proof-carrying synthesis and proof-automation technique, extending those proven successful on existing systems. This capability is crucial to meeting the cryptographic requirements for future high-consequence systems. Since specifications for high consequence cryptography are presently captured in a domain specific language known as Cryptol. While this can enable convenient fully automated reasoning about Cryptol specificaitons and implementations via the Software Analysis Workbench (SAW), Cryptol has expressivity gaps, so that cryptosystems with probabilistic programming features like Falcon cannot be fully expressed in the language. Moreover, SAW’s automation fails for programs and specificaitons with inductive and recursive structure, as in the Sphincs+ PQC. Finally, Cryptol and SAW together represent some 200,000 lines of unverified Haskell, so that the any guarantees about high consequence cryptography are presently contingent on a large, unverified, yet trusted computing base. The first step of the larger project of agile, assured crpytography is therefore to provide a formal, mechanized semantics for Cryptol, so that the specifications expressed by cryptographers in Cryptol can be reasoned about and compiled into performant implementations with a foundational, machine checkable certificate of correctness. This report describes our work on this first step, culminating in the design of a certified denotational interpreter, in Coq, for core Cryptol.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Efficiently improving the performance of noisy quantum computers

Using near-term quantum computers to achieve a quantum advantage requires efficient strategies to improve the performance of the noisy quantum devices presently available. We develop and experimentally validate two efficient error mitigation protocols named "Noiseless Output Extrapolation" and "Pauli Error Cancellation" that can drastically enhance the performance of quantum circuits composed of noisy cycles of gates. By combining popular mitigation strategies such as probabilistic error cancellation and noise amplification with efficient noise reconstruction methods, our protocols can mitigate a wide range of noise processes that do not satisfy the assumptions underlying existing mitigation protocols, including non-local and gate-dependent processes. We test our protocols on a four-qubit superconducting processor at the Advanced Quantum Testbed. We observe significant improvements in the performance of both structured and random circuits, with up to 86 % improvement in variation distance over the unmitigated outputs. Our experiments demonstrate the effectiveness of our protocols, as well as their practicality for current hardware platforms.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Fatty acid foams for nonselective physical removal of microplastics from aqueous solutions

Microplastics (MPs) are pervasive environmental contaminants whose removal from water remains a major challenge due to their small size, chemical diversity, and dynamic surface properties arising from environmental aging/weathering. Here, we present a concept of foam-based separation method that physically traps MPs in the foam phase using microtubular assemblies of 12-hydroxystearic acid. These foams are stabilized by anisotropic fatty acid microtubules formed in the presence of ethanolamine, which jam within the foam channels and suppress fluid drainage thereby enhancing MP retention and foam stability. MPs of different sizes, polymer compositions (including polystyrene, polypropylene, polyethylene terephthalate, and polytetrafluoroethylene), and weathered states were retained in the foam phase without requiring chemical modification or relying on chemical interactions between the fatty acid and MPs. Thermally induced transition of the fatty acid microtubules into nanomicelles above the characteristic phase transition temperature (∼35 °C) enables controlled foam collapse and recovery of trapped MPs. The cumulative removal efficiency can exceed 85% through multiple foaming cycles, matching predictions from a probabilistic retention model. This work shows that foams can provide a simple platform to trap MPs, thus providing a new physical-removal strategy that does not rely on the particles’ chemistry.

Guillot, Kennedy A. [Louisiana State Univ., Baton ↗

DOE OSTI2026

Enabling probabilistic learning on manifolds through double diffusion maps

Here, we present a generative learning framework for probabilistic sampling that extends Probabilistic Learning on Manifolds (PLoM), which is designed to generate statistically consistent realizations of a random vector in a finite-dimensional Euclidean space, informed by a (representative) set of observations. In its original form, PLoM constructs a reduced-order probabilistic model by combining three main components: (a) kernel density estimation to approximate the underlying probability measure, (b) Diffusion Maps to characterize the manifold of the data, and (c) a reduced-order Itô Stochastic Differential Equation (ISDE) to sample from the learned distribution. However, its sampling dynamics are posed in the ambient space and the retained number of reduced coordinates is chosen by projection-reconstruction error. In practice, this often (i) requires more coordinates than the data’s intrinsic dimension to achieve stable sampling and (ii) lacks a smooth, basis-independent lifting back to the data domain; moreover, standard Diffusion Maps emphasize harmonic eigenfunctions and can miss non-harmonic latent structure. We address these limitations by decoupling geometry learning from sampling: a first Diffusion Maps pass identifies non-harmonic coordinates on which we formulate a full-order ISDE directly in the latent space, while Double Diffusion Maps captures multiscale geometric features and Geometric Harmonics (GH) learns a smooth lifting map to the ambient variables that is independent of the particular diffusion basis. This hybrid design preserves the system’s dynamical richness with a compact geometric representation and enables principled out-of-sample inference. The effectiveness and robustness of the proposed method are illustrated through two numerical studies: one based on data generated from two-dimensional Hermite polynomial functions and another based on high-fidelity simulations of a detonation wave in a reactive flow.

Double diffusion maps↗

DOE OSTI2025

Data-Efficient Strategies for Probabilistic Voltage Envelopes under Network Contingencies

This work presents an efficient data-driven method to construct probabilistic voltage envelopes (PVE) using power flow learning in grids with network contingencies. First, a network-aware Gaussian process (GP) termed Vertex-Degree Kernel (VDK-GP), developed in prior work, is used to estimate voltage–power functions for a few network configurations. The paper introduces a novel multi-task vertex degree kernel (MT-VDK) that amalgamates the learned VDK-GPs to determine power flows for unseen networks, with a significant reduction in the computational complexity and hyperparameter requirements compared to alternate approaches. Simulations on the IEEE 30-Bus network demonstrate the retention and transfer of power flow knowledge in both N-1 and N-2 contingency scenarios. The MT-VDK-GP approach achieves over 50 % reduction in mean prediction error for novel N-1 contingency network configurations in low training data regimes (50–250 samples) over VDK-GP. Additionally, MT-VDK-GP outperforms a hyper-parameter based transfer learning approach in over 75 % of N-2 contingency network structures, even without historical N-2 outage data. Furthermore, the proposed method demonstrates the ability to achieve PVEs using sixteen times fewer power flow solutions compared to Monte-Carlo sampling-based methods.

24 POWER TRANSMISSION AND DISTRIBUTION↗