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DOE OSTI2025

Machine Learning for Automated Weld Quality Monitoring and Control

Resistance Spot Welding (RSW) is a critical process in the automotive industry, valued for its cost-effectiveness, short cycle time, and robustness. However, achieving consistent high-quality joints remains challenging due to the complex interplay of various factors, like materials, processes, and manufacturing uncertainties, etc. Under the collaborative project between Oak Ridge National Laboratory (ORNL) and General Motors (GM), we have developed a robust and expansible machine learning (ML) framework aimed at enhancing quality control in RSW. By harnessing the power of machine learning, we have developed the ability to ensure every aspect of the welding process, from the initial process design stage to the final weld joint quality. The framework operates by analyzing a variety of data streams, including in-line process signals, process parameters, materials, and postprocessed weld joint data. Through this analysis, the models have been trained to detect deviations from optimal quality standards, leveraging their ability to identify signature data patterns and anomalies within in-line signals and construct complex correlations between these signals and weld quality parameters. Meanwhile, the machine learning framework is designed to adapt to a variety of materials, including high strength steels and aluminum alloys, etc. Its flexible architecture facilitates the incorporation of diverse data sources and features, enabling precise modeling and prediction across a broad range of material properties and weld quality variables. The expansible ML frameworks represent a promising transformation in weld quality monitoring and control, empowering industry to achieve high levels of efficiency, consistency, and reliability in manufacturing.

42 ENGINEERING↗

NASA NTRS1973

ERIM progress report on use of ERTS-1 data: Summary report of work on ten tasks

The author has identified the following significant results. Several of the tasks have produced significant results which are summarized: (1) Absolute water depth can be calculated from a ratio of signals from bands MSS 4 and MSS 5. (2) A 13 category terrain feature classification map of Yellowstone National Park has been produced using supervised pattern recognition techniques. (3) ERTS-1 data has been shown to provide a detection and monitoring capability for a number of water quality problems associated with off-shore ocean dumping sites and inland lakes. (4) A corrected ratio of bands MSS-5 and MSS-7 signals has been formed. (5) A concise format has been devised for storing the ratio signatures of geologic rock and mineral materials determined from laboratory reflectance spectra. (6) Results of work in information extraction demonstrate: signal variability exists among ERTS-1 detectors in any one spectral band that will impact users doing quantitative analysis on successive ERTS-1 images; a newly developed computer-aided procedure for correlating ERTS-1 pixels to ground features; the strong influence of atmospheric effects in ERTS-1 data; and area estimation accuracies are better using the ERIM proportion estimation algorithm than for conventional recognition techniques.

Thomson, F. J.↗

NASA NTRS1974

ERTS-1 flood hazard studies in the Mississippi River Basin

The Spring 1973 Mississippi River flood was investigated using remotely sensed data from ERTS-1. Both manual and automatic analyses of the data indicate that ERTS-1 is extremely useful as a regional tool for flood and floodplain management. The maximum error of such flood area measurements is conservatively estimated to be less than five percent. Change detection analysis indicates that the flood had major impacts on soil moisture, land pattern stability, and vegetation stress. Flood hazard identification was conducted using photointerpretation techniques in three study areas along the Mississippi River using pre-flood ERTS-1 imagery down to 1:100,000 scale. Flood prone area boundaries obtained from ERTS-1 were generally in agreement with flood hazard maps produced by the U.S. Army Corps of Engineers and the U.S. Geological Survey although the latter are somewhat more detailed because of their larger scale. Initial results indicate that ERTS-1 digital mapping of the flood-prone areas can be performed at least 1:62,500 which is comparable to conventional flood hazard map scales.

Rango, A.↗

NASA NTRS1983

Acoustooptic pulse-echo transducer system

A pulse-echo transducer system which uses an ultrasonic generating element and an optical detection technique is described. The transmitting transducer consists of a concentric ring electrode pattern deposited on a circular, X-cut quartz substrate with a circular hole in the center. The rings are independently pulsed with a sequence high voltage signals phased in such a way that the ultrasonic waves generated by the separate rings superimpose to produce a composite field which is focused at a controllable distance below the surface of the specimen. The amplitude of the field reflected from this focus position is determined by the local reflection coefficient of the medium at the effective focal point. By processing the signals received for a range of ultrasonic transducer array focal lengths, the system can be used to locate and size anomalies within solids and liquids. Applications in both nondestructive evaluation and biomedical scanning are suggested.

Claus, R. O.↗

NASA NTRS1988

Reflectance spectra of subarctic lichens

Lichens constitute a major portion of the ground cover of high latitude environments, but little has been reported concerning their in situ solar spectral reflectance properties. Knowledge of these properties is important for the interpretation of remotely sensed observations from high latitude regions, as well as in studies of high latitude ecology and energy balance climatology. The spectral reflectance of common boreal vascular plants is similar to that of vascular plants of the midlatitudes. The dominant lichens, in contrast, display variable reflectance patterns in visible wavelengths. The relative reflectance peak at 0.55 microns, common to green vegetation, is absent or indistinct in spectra of pervasive boreal forest and tundra lichens, despite the presence of chlorophyll in the inner algal cells. Lichens of the dominant genus, Cladina, display strong absorption of ultraviolet energy and short-wavelength blue light relative to their absorption in other visible wavelengths. Since the Cladinae dominate both the surface vegetation in open woodlands of the boreal forest and the low arctic tundra, their unusual spectral reflectance patterns will enable accurate monitoring of the boreal forest-tundra ecotone and detection of its vigor and movement in the future.

Petzold, Donald E.↗

NASA NTRS1989

Flat field response of the microchannel plate detectors used on the Extreme Ultraviolet Explorer

The results of the extreme ultraviolet (EUV) flat field calibrations of two of the flight detectors to be flown on the Extreme Ultraviolet Explorer Satellite (EUVE) are presented. Images of about 40 million detected events binned 512 by 512 are sufficient to show microchannel plate fixed pattern noise such as hexagonal microchannel multifiber bundle interfaces, 'dead' spots, edge distortion, and differential nonlinearity. Differences due to photocathode material and dependencies on EUV wavelength are also described. Over large spatial scales, the detector response is flat to better than 10 percent of the mean response, but, at spatial scales less than 1 mm, the variations from the mean can be as large as 20 percent.

Vallerga, J. V.↗

NASA NTRS2003

Gone But Not Forgotten: The Aeolian Modification of Fluvial Surfaces on Mars: Preliminary Results from Central Australia

MOC images indicate that aeolian ridges may mask and even obliterate primary depositional surfaces on Mars. This modification increases the difficulty in mapping the recent geological history of the planet. An analogue study in central Australia demonstrates how patterns in aeolian dunes, formed over abandoned fluvial surfaces, can be used to detect buried fluvial features.

Bourke, M. C.↗

NASA NTRS2008

Patterns of Error in Confidential Maintenance Incident Reports

Confidential reports of maintenance incidents are a valuable source of information on maintenance errors and the contexts within which they occur. NASA's Aviation Safety Reporting System (ASRS) has been receiving an increasing number of maintenance incident reports since a specialized maintenance reporting form was introduced in 1996. In a series of studies, the database of ASRS maintenance incidents was examined using correspondence analysis, a statistical technique that converts complex data tables into a visual form. The analyses revealed patterns within the ASRS data set that would have otherwise been difficult to detect. The results have implications for a range of purposes including human factors training, the design of procedures, and the identification of improvements in aircraft design.

Hobbs, Alan↗

NASA NTRS2013

Progress of a Cross-correlation Based Optical Strain Measurement Technique for Detecting Radial Growth on a Rotating Disk

The Aeronautical Sciences Project under NASAs Fundamental Aeronautics Program is extremely interested in the development of fault detection technologies, such as optical surface measurements in the internal parts of a flow path, for in situ health monitoring of gas turbine engines. In situ health monitoring has the potential to detect flaws, i.e. cracks in key components, such as engine turbine disks, before the flaws lead to catastrophic failure. In the present study, a cross-correlation imaging technique is investigated in a proof-of-concept study as a possible optical technique to measure the radial growth and strain field on an already cracked sub-scale turbine engine disk under loaded conditions in the NASA Glenn Research Centers High Precision Rotordynamics Laboratory. The optical strain measurement technique under investigation offers potential fault detection using an applied background consisting of a high-contrast random speckle pattern and imaging the background under unloaded and loaded conditions with a CCD camera. Spinning the cracked disk at high speeds induces an external load, resulting in a radial growth of the disk of approximately 50.8-m in the flawed region and hence, a localized strain field. When imaging the cracked disk under static conditions, the disk will appear shifted. The resulting background displacements between the two images will then be measured using the two-dimensional cross-correlation algorithms implemented in standard Particle Image Velocimetry (PIV) software to track the disk growth, which facilitates calculation of the localized strain field. In order to develop and validate this optical strain measurement technique an initial proof-of-concept experiment is carried out in a controlled environment. Using PIV optimization principles and guidelines, three potential backgrounds, for future use on the rotating disk, are developed and investigated in the controlled experiment. A range of known shifts are induced on the backgrounds; reference and data images are acquired before and after the induced shift, respectively, and the images are processed using the cross- correlation algorithms in order to determine the background displacements. The effectiveness of each background at resolving the known shift is evaluated and discussed in order to choose to the most suitable background to be implemented onto a rotating disk in the Rotordynamics Lab. Although testing on the rotating disk has not yet been performed, the driving principles behind the development of the present optical technique are based upon critical aspects of the future experiment, such as the amount of expected radial growth, disk analysis, and experimental design and are therefore addressed in the paper.

Clem, Michelle M.↗

NASA NTRSDate not supplied

The Completion of a Geosynchronous Earth Orbit Survey with the Eugene Stansbery-Meter Class Autonomous Telescope

The Eugene Stansbery-Meter Class Autonomous Telescope (ES-MCAT) is the primary optical sensor used by the NASA Orbital Debris Program Office (ODPO) to statistically characterize the geosynchronous Earth orbit (GEO) debris environment and support future Orbital Debris Engineering Model (ORDEM) releases. The ES-MCAT completed its first optical survey of the GEO region from 2020 to 2022. The primary goal of this survey was to autonomously collect and process GEO data with calculated photometric and astrometric uncertainties. A pointing plan was developed to provide uniform sampling within the region of interest (ROI) while accounting for predicted downtime due to insufficient observing conditions. Detections are autonomously correlated to the Space Surveillance Network (SSN) catalog to determine if objects are correlated targets (CTs) or uncorrelated targets (UCTs), the latter of which are of interest for modeling the GEO orbital debris environment. To assess the size detection sensitivity over time and monitor the general performance of the telescope’s optics and software, the optical throughput of the system and limiting magnitudes are evaluated on a routine basis. While the telescope’s ability to operate autonomously and remotely allowed for the GEO survey to continue throughout the COVID-19 pandemic, travel restrictions hampered routine cleaning of the optics during this time, and the primary mirror degraded enough to require recoating. The mirror was removed in 2022, concluding the first GEO survey. The primary mirror received a new coating designed to be more robust against the harsh environment surrounding the ES-MCAT’s location on Ascension Island, accounting for experience gained during operations over the first GEO survey. In early 2023, the recoated primary mirror was reinstalled, and the second GEO survey was initiated. The primary goal of the second GEO survey is to characterize the evolving GEO debris environment with updated optics, software, and pointing strategies while allowing for the inclusion of non-GEO regimes or those that are outside of the ROI. While the pointing method implemented in the first survey allowed for adequate coverage of the ROI over two years, it has been improved to include pointings that avoid the Moon’s position and the galactic plane to reduce software processing time and maximize the detection capabilities of fainter objects. This method also accounts for the changing weather patterns throughout the year and reduces coverage gaps in the ROI. Provided the success of the first two-year GEO survey using autonomous operations, the ODPO is actively collaborating with the United States Space Force (USSF) to make the ES-MCAT a contributing sensor to the SSN. This paper presents results from the first GEO survey including magnitude distributions and orbital parameters for CTs and UCTs. Details are provided for the automated processing pipeline and the optical system throughput for the previous and current primary mirror coatings. In addition, an updated strategy for the second GEO survey to optimize coverage over the ROI is discussed, as are preliminary results from the ongoing second survey.

Corbin Cruz↗

NASA NTRSDate not supplied

The Completion of a Geosynchronous Earth Orbit Survey with the Eugene Stansbery-Meter Class Autonomous Telescope

Corbin Cruz↗

DOE OSTI2020

Systematic Evaluation of Backdoor Data Poisoning Attacks on Image Classifiers

Backdoor data poisoning attacks have recently been demonstrated in computer vision research as a potential safety risk for machine learning (ML) systems. Traditional data poisoning attacks manipulate training data to induce unreliability of an ML model, whereas backdoor data poisoning attacks maintain system performance unless the MLmodel is presented with an input containing an embedded“trigger” that provides a predetermined response advantageous to the adversary. Our work builds upon prior back-door data-poisoning research for ML image classifiers and systematically assesses different experimental conditions including types of trigger patterns, persistence of trigger patterns during retraining, poisoning strategies, architectures (ResNet-50, NasNet, NasNet-Mobile), datasets (Flowers, CIFAR-10), and potential defensive regularization techniques (Contrastive Loss, Logit Squeezing, Manifold Mixup,Soft-Nearest-Neighbors Loss). Experiments yield four key findings. First, the success rate of backdoor poisoning at-tacks varies widely, depending on several factors, including model architecture, trigger pattern and regularization technique. Second, we find that poisoned models are hard to detect through performance inspection alone. Third, regularization typically reduces backdoor success rate, although it can have no effect or even slightly increase it, depending on the form of regularization. Finally, backdoors inserted through data poisoning can be rendered ineffective after just a few epochs of additional training on a small set of clean data without affecting the model’s performance.

Truong, Loc T.↗

DOE OSTI2021

A Novel Fiber-Bragg-Grating-Based Unique Identifier for Use in Tags and Seals

Tags and seals are important tools used in safeguards regimes for the control of nuclear materials. Vital to a successful tag or seal is the ability to securely, uniquely, and positively distinguish it from others of the same kind. This allows one to validate that items entered into an inspection regime to which the tag or seal is affixed are as claimed. We are developing a new type of unique identifier (UID) for such applications that is based on fiber-Bragg grating (FBG) technology. The index of refraction of the core glass of a fiber optic can be locally and permanently altered if sensitized fibers are exposed to intense ultraviolet light. This can be used to create index modulations with a regular periodicity comparable to the wavelengths of light with which the fiber is used. If broadband illumination is sent down the fiber, any light that is in resonance with the modulations will be reflected back to the input end of the fiber where it can be detected. The shape of the returned spectrum can be set by the modulation pattern written into the fiber’s core. We take advantage of these properties to create a compact UID that contains several FBGs potted into a monolithic body. By connecting the UID to an optical interrogator, the complex spectral return can be uniquely identified with a short measurement, providing a robust identification. As a device based on narrowband spectral returns, FBGs are inherently radiation tolerant, making them ideal for use with nuclear materials. Further, they can be read out remotely via a long fiber optic or locally via brief connection to a portable optical interrogator. Because the spectral signature of FBGs is sensitive to external mechanical perturbations, we are exploring the ability to reversibly alter the signature obtained from the UID by applying controlled mechanical forces with a simple device. Such a “key” will allow different stakeholders to obtain their own unique signature from the device, providing a new level of surety to safeguards inspections.

Ziock, Klaus-Peter↗

DOE OSTI2023

Coded-mask-based X-ray phase-contrast and dark-field imaging

Phase contrast and dark-field X-ray imaging enable imaging of objects that absorb or reflect very little X-ray light. Disclosed is a method and systems for performing coded-mask-based multi-contrast imaging (CMMI). The method includes providing radiation to a coded mask that has a known phase and absorption profile according to a pre-determined pattern. The radiation is then impingent upon a sample, and the radiation is detected to perform phase-reconstruction and image processing. The method and associated systems allow for the use of maximum-likelihood and machine learning methods for reconstruction images of the sample from the detected radiation.

Shi, Xianbo↗

DOE OSTI2016

Iterative Strategies for Aftershock Classification in Automatic Seismic Processing Pipelines

We report aftershock sequences following very large earthquakes present enormous challenges to near-real-time generation of seismic bulletins. The increase in analyst resources needed to relocate an inflated number of events is compounded by failures of phase-association algorithms and a significant deterioration in the quality of underlying, fully automatic event bulletins. Current processing pipelines were designed a generation ago, and, due to computational limitations of the time, are usually limited to single passes over the raw data. With current processing capability, multiple passes over the data are feasible. Processing the raw data at each station currently generates parametric data streams that are then scanned by a phase-association algorithm to form event hypotheses. We consider the scenario in which a large earthquake has occurred and propose to define a region of likely aftershock activity in which events are detected and accurately located, using a separate specially targeted semiautomatic process. This effort may focus on so-called pattern detectors, but here we demonstrate a more general grid-search algorithm that may cover wider source regions without requiring waveform similarity. Given many well-located aftershocks within our source region, we may remove all associated phases from the original detection lists prior to a new iteration of the phase-association algorithm. We provide a proof-of-concept example for the 2015 Gorkha sequence, Nepal, recorded on seismic arrays of the International Monitoring System. Even with very conservative conditions for defining event hypotheses within the aftershock source region, we can automatically remove about half of the original detections that could have been generated by Nepal earthquakes and reduce the likelihood of false associations and spurious event hypotheses. Lastly, further reductions in the number of detections in the parametric data streams are likely, using correlation and subspace detectors and/or empirical matched field processing.

58 GEOSCIENCES↗

DOE OSTI2018

Explosion-Generated Infrasound Recorded on Ground and Airborne Microbarometers at Regional Distances

Recent work in deploying infrasound (low–frequency sound) sensors on aerostats and free–flying balloons has shown them to be viable alternatives to ground stations. However, no study to date has compared the performance of surface and free–floating infrasound microbarometers with respect to acoustic events at regional (100s of kilometers) range. The prospect of enhanced detection of aerial explosions at similar ranges, such as those from bolides, has not been investigated either. We examined infrasound signals from three 1–ton trinitrotoluene (TNT) equivalent chemical explosions using microbarometers on two separate balloons at 280– to 400–km ranges and ground stations at 6.3– to 350–km ranges. Signal celerities were consistent with acoustic waves traveling in the stratospheric duct. However, significant differences were noted between the observed arrival patterns and those predicted by an acoustic propagation model. Very low–background noise levels on the balloons were consistent with previous studies that suggest wind interference is minimal on freely drifting sensors. In conclusion, simulated propagation patterns and observed noise levels also confirm that balloon–borne microbarometers should be very effective at detecting explosions in the middle and upper atmosphere as well as those on the surface.

58 GEOSCIENCES↗

DOE OSTI2015

Nitrogen-modified nano-titania: True phase composition, microstructure and visible-light induced photocatalytic NO{sub x} abatement

Titanium dioxide (TiO{sub 2}) is a popular photocatalyst used for many environmental and anti-pollution applications, but it normally operates under UV light, exploiting ∼5% of the solar spectrum. Nitrification of titania to form N-doped TiO{sub 2} has been explored as a way to increase its photocatalytic activity under visible light, and anionic doping is a promising method to enable TiO{sub 2} to harvest visible-light by changing its photo-absorption properties. In this paper, we explore the insertion of nitrogen into the TiO{sub 2} lattice using our green sol–gel nanosynthesis method, used to create 10 nm TiO{sub 2} NPs. Two parallel routes were studied to produce nitrogen-modified TiO{sub 2} nanoparticles (NPs), using HNO{sub 3}+NH{sub 3} (acid-precipitated base-peptised) and NH{sub 4}OH (totally base catalysed) as nitrogen sources. These NPs were thermally treated between 450 and 800 °C. Their true phase composition (crystalline and amorphous phases), as well as their micro-/nanostructure (crystalline domain shape, size and size distribution, edge and screw dislocation density) was fully characterised through advanced X-ray methods (Rietveld-reference intensity ratio, RIR, and whole powder pattern modelling, WPPM). As pollutants, nitrogen oxides (NO{sub x}) are of particular concern for human health, so the photocatalytic activity of the NPs was assessed by monitoring NO{sub x} abatement, using both solar and white-light (indoor artificial lighting), simulating outdoor and indoor environments, respectively. Results showed that the onset of the anatase-to-rutile phase transformation (ART) occurred at temperatures above 450 °C, and NPs heated to 450 °C possessed excellent photocatalytic activity (PCA) under visible white-light (indoor artificial lighting), with a PCA double than that of the standard P25 TiO{sub 2} NPs. However, higher thermal treatment temperatures were found to be detrimental for visible-light photocatalytic activity, due to the effects of four simultaneous occurrences: (i) loss of OH groups and water adsorbed on the photocatalyst surface; (ii) growth of crystalline domain sizes with decrease in specific surface area; (iii) onset and progress of the ART; (iv) the increasing instability of the nitrogen in the titania lattice. - Graphical abstract: Nitrogen modified TiO{sub 2} synthesised via a green aqueous sol–gel method showed to degrade nitrogen oxides (NO{sub x}) under visible white-light (indoor artificial lighting), with a photocatalytic activity double than that of the standard P25 TiO{sub 2} NPs. - Highlights: • N–TiO{sub 2} synthesised via a green aqueous sol–gel method. • Advanced X-ray methods used to detect both crystalline and amorphous contents. • Microstructure fully addressed via XRPD and whole powder pattern modelling. • Photocatalytic NO{sub x} removal assessed using both solar and visible-light lamps.

36 MATERIALS SCIENCE↗

NASA NTRS2023

Far-Infrared Line Emission from the Outer Galaxy Cluster Gy 3–7 With SOFIA/FIFI-LS: Physical Conditions and UV Fields

Context. Far-infrared (FIR) line emission provides key information about the gas cooling and heating due to shocks and UV radiation associated with the early stages of star formation. Gas cooling via FIR lines might, however, depend on metallicity. Aims. We aim to quantify the FIR line emission and determine the spatial distribution of the CO rotational temperature, ultraviolet (UV) radiation field, and H2 number density toward the embedded cluster Gy 3–7 in the CMa–l224 star-forming region, whose metallicity is expected to be intermediate between that of the Large Magellanic Cloud and the Solar neighborhood. By comparing the total luminosities of CO and [O I] toward Gy 3–7 with values found for low- and high-mass protostars extending over a broad range of metallicities, we also aim to identify the possible effects of metallicity on the FIR line cooling within our Galaxy. Methods. We studied SOFIA/FIFI-LS spectra of Gy 3–7, covering several CO transitions from J = 14–13 to 31-30, the OH doublet at 79 µm, the [O I] 63.2 and 145.5 µm, and the [C II] 158 µm lines. The field of view covers a 2 0 × 1 0 region with a resolution of ∼7 00–1800 . Results. The spatial extent of CO high-J (Jup ≥14) emission resembles that of the elongated 160 µm continuum emission detected with Herschel, but its peaks are offset from the positions of the dense cores. The [O I] lines at 63.2 µm and 145.5 µm follow a similar pattern, but their peaks are found closer to the positions of the cores. The CO transitions from J = 14–13 to J = 16–15 are detected throughout the cluster and show a median rotational temperature of 170 ± 30 K on Boltzmann diagrams. Comparisons to other protostars observed with Herschel show a good agreement with intermediate-mass sources in the inner Galaxy. Assuming an origin of the [O I] and high-J CO emission in UV-irradiated C−shocks, we obtained pre-shock H2 number densities of 104–105 cm−3 and UV radiation field strengths of 0.1–10 Habing fields (G0). Conclusions. Far-IR line observations reveal ongoing star formation in Gy 3–7, dominated by intermediate-mass Class 0/I young stellar objects. The ratio of molecular-to-atomic far-IR line emission shows a decreasing trend with bolometric luminosities of the protostars. However, it does not indicate that the low-metallicity has an impact on the line cooling in Gy 3–7.

stars: formation↗