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DOE OSTI2026

In-situ sensor monitoring of multi-class gas porosity formation in laser powder bed fusion using convolutional neural network

In-situ monitoring of defect formation remains a significant challenge in the laser powder bed fusion (LPBF) process. Recent advances have enabled real-time defect detection with machine learning and in-situ sensing technologies; however, most studies focus on binary classification of keyhole pores, limiting nuanced multi-class pore differentiation and formation mechanisms. This work introduces a multi-class pore detection framework (no pore, small pores < 15 µm, and large pores > 15 µm) by leveraging photodiode sensor data alongside high-fidelity synchrotron X-ray imaging. The 15 µm threshold is selected to distinguish between two fundamentally different defect mechanisms, following the physical size-mechanism boundary established by prior high-resolution synchrotron X-ray characterization of Al6061 LPBF. Distinguishing these classes is critical because large keyhole pores are structurally detrimental, whereas small gas pores are often benign, requiring different process control strategies. Thermal emission monitoring data collected simultaneously with high-speed X-ray imaging at the Stanford Synchrotron Radiation Lightsource (SSRL), are correlated with subsurface melt pool dynamics to establish ground truth. Continuous Wavelet Transform (CWT) with optimized parameters converts the photodiode time-series signals into time–frequency images, facilitating feature extraction. Convolutional Neural Networks (CNN) are then applied for real-time multi-class pore classification in an average inference time of 1 ms per signal window. It achieves 79% accuracy and an Area Under the Receiver Operating Characteristic curve (AUC ROC) score of 0.89 with five-fold cross-validation. The results demonstrate that coupling CWT-based feature engineering with CNN architecture enables reliable multi-class pore detection in Al6061 builds using affordable in-situ sensors. This approach advances scalable and affordable quality assurance in additive manufacturing by moving beyond binary defect detection toward more nuanced classification of porosity mechanisms with in-situ sensors and machine learning.

Laser powder bed fusion, Multi-class pores, In-sit↗

DOE OSTI2026

Predicting U 3 O 8 powder processing conditions: An AI/ML approach analyzing deep learning embeddings of SEM micrographs

High-resolution SEM images of uranium-oxide powders encode micro- and nanoscale clues to their synthesis route and calcination temperature. We trained a ResNet-50 model on 11 commercial-scale U₃O₈ classes, ammonium diuranate (ADU) or uranyl peroxide (H₂O₂) precursors calcined at temperatures ranging from 400 to 750 °C and added a 256-D projection head before the classifier to analyze the learned representation. The best of eight seeds reached 92.4 % accuracy on reserved testing data, but our focus is the structure of the embedding space rather than the accuracy and labels. We quantify class relatedness in the original 256-D space using centroid similarity and distributional distances, and we use Uniform Manifold Approximation Projection (UMAP) for visualization. ‘Unknown’ images from different preparation methods, SEM operators, and from the literature localized near the expected classes under a nearest-centroid analysis without retraining, as well as clustered in similar UMAP space. In conclusion, this embedding-centered workflow complements black-box classification by providing quantitative, similarity-based comparisons of U₃O₈ morphologies and reduces storage space by up to 98 % for image data used in millisecond vector search comparisons.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Elliptically-Contoured Tensor-variate Distributions with Application to Image Learning

Statistical analysis of tensor-valued data has largely used the tensor-variate normal (TVN) distribution that may be inadequate for data arising from distributions with heavier or lighter tails. We study a general family of elliptically contoured (EC) TV distributions and derive its characterizations, moments, marginal, and conditional distributions. We describe procedures for maximum likelihood estimation from data that are (1) uncorrelated draws from an EC distribution, (2) from a scale mixture of the TVN distribution, and (3) from an underlying but unknown EC distribution, for which we extend Tyler’s robust estimator. A detailed simulation study highlights the benefits of choosing an EC distribution over the TVN for heavier-tailed data. We develop TV classification rules using discriminant analysis and EC errors and show that they better predict cats and dogs from images in the Animal Faces-HQ dataset than the TVN-based rules. A novel tensor-on-tensor regression and TV analysis of variance (TANOVA) framework under EC errors is also demonstrated to better characterize gender, age, and ethnic origin than the usual TVN-based TANOVA in the celebrated labeled faces of the wild dataset.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Identifying the quantum properties of hadronic resonances using machine learning

With the great promise of deep learning, discoveries of new particles at the Large Hadron Collider (LHC) may be imminent. Following the discovery of a new Beyond the Standard model particle in an all-hadronic channel, deep learning can also be used to identify its quantum numbers. Convolutional neural networks (CNNs) using jet-images can significantly improve upon existing techniques to identify the quantum chromodynamic (QCD) (‘color’) as well as the spin of a two-prong resonance using its substructure. Additionally, jet-images are useful in determining what information in the jet radiation pattern is useful for classification, which could inspire future taggers. These techniques improve the categorization of new particles and are an important addition to the growing jet substructure toolkit, for searches and measurements at the LHC now and in the future.

Filipek, Jakub↗

DOE OSTI2025

Dark Energy Survey Year 6 Results: Synthetic-source Injection Across the Full Survey Using Balrog

Synthetic source injection (SSI), the insertion of sources into pixel-level on-sky images, is a powerful method for characterizing object detection and measurement in wide-field, astronomical imaging surveys. Within the Dark Energy Survey (DES), SSI plays a critical role in characterizing all necessary algorithms used in converting images to catalogs, and in deriving quantities needed for the cosmology analysis, such as object detection rates, galaxy redshift estimation, galaxy magnification, star-galaxy classification, and photometric performance. We present here a source injection catalog of 146 million injections spanning the entire 5000 deg 2 DES footprint, generated using the Balrog SSI pipeline. Through this SSI sample, we demonstrate that the DES Year 6 (Y6) image processing pipeline provides accurate estimates of the object properties, for both galaxies and stars, at the percent-level, and we highlight specific regimes where the accuracy is reduced. We then show the consistency between SSI and data catalogs, for all galaxy samples developed within the weak lensing and galaxy clustering analyses of DES Y6. The consistency between the two catalogs also extends to their correlations with survey observing properties (seeing, airmass, depth, extinction, etc.). Lastly, we highlight a number of applications of this catalog to the DES Y6 cosmology analysis, such as estimates of the redshift distribution and lens magnification. This dataset is the largest SSI catalog produced at this fidelity and will serve as a key testing ground for exploring the utility of SSI catalogs in upcoming surveys such as the Vera C. Rubin Observatory Legacy Survey of Space and Time.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2025

From pixels to patterns: Coupling Optical Coherence Tomography and machine learning for monitoring coastal wetland root systems

Coastal wetlands are crucial in shoreline stabilization, carbon sequestration, and storm protection. Yet, due to limitations in traditional destructive sampling techniques, the belowground biomass (live root mass) and necromass (dead and decaying roots) remain difficult to assess in coastal wetlands, limiting our understanding on coastal resilience, nutrient cycling, and soil structure. This study employs Optical Coherence Tomography (OCT) as a high-resolution imaging technique to analyze root biomass and necromass in the Terrebonne Basin, Louisiana. A Random Forest (RF) model was developed to classify root health states based on OCT-derived features, achieving an accuracy of 70% in distinguishing live from dead root segments. The results demonstrate that OCT, combined with ML, offers a promising novel approach to root analysis, providing fine-scale insights into root morphology and decay patterns that are not easily captured by conventional methods. This research lays the foundation for future integration of OCT with complementary imaging modalities such as X-ray Computed Tomography (XCT) and advanced ML algorithms to enhance classification accuracy and scalability. Future work aims to expand the dataset diversity across different wetland types and apply the methodology for large-scale, repeatable assessments of root biomass turnover and accumulation, with important implications for wetland monitoring, conservation, and restoration under changing environmental conditions.

AI/ML↗

DOE OSTI2026

Detection and imaging of chemicals and hidden explosives using terahertz time-domain spectroscopy and deep learning

Detecting concealed chemicals and explosives remains a critical challenge in global security. Terahertz time-domain spectroscopy (THz-TDS) offers a promising non-invasive and stand-off detection technique owing to its ability to penetrate optically opaque materials without causing ionization damage. While many chemicals exhibit distinct spectral features in the terahertz range, conventional terahertz-based detection methods often struggle in real-world environments, where variations in sample geometry, thickness, and packaging can lead to inconsistent spectral responses. In this study, we present a chemical imaging system that integrates THz-TDS with deep learning to enable accurate pixel-level identification and classification of different explosives. Operating in reflection mode and enhanced with plasmonic nanoantenna arrays, our THz-TDS system achieves a peak dynamic range of 96 dB and a detection bandwidth of 4.5 THz, supporting practical, stand-off operation. By analyzing individual time-domain pulses with deep neural networks, the system exhibits strong resilience to environmental variations and sample inconsistencies. Blind testing across eight chemicals—including pharmaceutical excipients and explosive compounds—resulted in an average classification accuracy of 99.42% at the pixel level. Notably, the system maintained an average accuracy of 88.83% when detecting explosives concealed under opaque paper coverings, demonstrating its robust generalization capability. These results highlight the potential of combining advanced terahertz spectroscopy with neural networks for highly sensitive and specific chemical and explosive detection in diverse and operationally relevant scenarios.

Imaging and sensing↗

DOE OSTI2024

YOLO for Radio Frequency Signal Classification

Radio frequency signal classification plays a pivotal role in various applications, including spectrum management, wireless security, and cognitive radio. Extant signal classification methods require significant data throughput and are not multilabel. We propose a novel approach to radio frequency signal classification by leveraging the You Only Look Once (YOLO) object detection method. YOLO is a state-of-the-art deep learning model renowned for its real-time object detection capabilities in computer vision applications. We adapt YOLO for signal classification to enable the automatic and efficient identification of various signal types within a power spectral density image. Index Terms—radio-frequency analysis, object detection, neural networks, machine learning, deep learning.

42 ENGINEERING↗

DOE OSTI2025

Mind the gap: Bridging the divide between AI aspirations and the reality of autonomous microscopy

What does materials science look like in the “Age of Artificial Intelligence?” Each material’s domain—synthesis, characterization, and modeling—has a different answer to this question, motivated by unique challenges and constraints. This work focuses on the tremendous potential of autonomous characterization within electron microscopy. We present our recent advancements in developing domain-aware, multimodal models for microscopy analysis capable of describing complex atomic systems. We then address the critical gap between the theoretical promise of autonomous microscopy and its current practical limitations, showcasing recent successes while highlighting the necessary developments to achieve robust, real-world autonomy.

2D materials↗

DOE OSTI2024

Quantum Vision Transformers for Quark–Gluon Classification

We introduce a hybrid quantum-classical vision transformer architecture, notable for its integration of variational quantum circuits within both the attention mechanism and the multi-layer perceptrons. The research addresses the critical challenge of computational efficiency and resource constraints in analyzing data from the upcoming High Luminosity Large Hadron Collider, presenting the architecture as a potential solution. In particular, we evaluate our method by applying the model to multi-detector jet images from CMS Open Data. The goal is to distinguish quark-initiated from gluon-initiated jets. We successfully train the quantum model and evaluate it via numerical simulations. Using this approach, we achieve classification performance almost on par with the one obtained with the completely classical architecture, considering a similar number of parameters.

Comajoan Cara, Marçal (ORCID:0009000126263752)↗

DOE OSTI2026

Micro-photoluminescence mapping and Chemometrics for the rapid classification of rare earth materials

This article introduces advancements in chemically mapping rare earth materials using photoluminescence (PL) and chemometrics. By leveraging the high sensitivity and selectivity of PL compared to alternative optical techniques, as well as its compatibility with microscopy, we present enhanced capabilities for noninvasive material screening and characterization. Exemplary PL spectra of samarium(III) and europium(III) in oxide, nitrate, and chloride forms demonstrated the ability to extract detailed chemical information of diverse rare earth particles. Additionally, we introduced efficient PL mapping sequences capable of covering a 9 mm diameter carbon tab within minutes, which highlighted the benefits of rapid, large-area imaging. Furthermore, an integrated approach combining PL mapping with principal component analysis and a random forest classifier enabled the resolution of overlapping spectral peaks from different chemistries and provided accurate material classification. In conclusion, these advancements underscored the versatility and robustness of PL for chemically mapping rare earth materials, with the potential to support applications in mining, energy, environmental monitoring, isotope production and beyond.

Chemometrics↗

DOE OSTI2024

Recovered supernova Ia rate from simulated LSST images

Aims.TheVera C. RubinObservatory’s Legacy Survey of Space and Time (LSST) will revolutionize time-domain astronomy by detecting millions of different transients. In particular, it is expected to increase the number of known type Ia supernovae (SN Ia) by a factor of 100 compared to existing samples up to redshift ∼1.2. Such a high number of events will dramatically reduce statistical uncertainties in the analysis of the properties and rates of these objects. However, the impact of all other sources of uncertainty on the measurement of the SN Ia rate must still be evaluated. The comprehension and reduction of such uncertainties will be fundamental both for cosmology and stellar evolution studies, as measuring the SN Ia rate can put constraints on the evolutionary scenarios of different SN Ia progenitors. Methods.We used simulated data from the Dark Energy Science Collaboration (DESC) Data Challenge 2 (DC2) and LSST Data Preview 0 to measure the SN Ia rate on a 15 deg 2 region of the “wide-fast-deep” area. We selected a sample of SN candidates detected in difference images, associated them to the host galaxy with a specially developed algorithm, and retrieved their photometric redshifts. We then tested different light-curve classification methods, with and without redshift priors (albeit ignoring contamination from other transients, as DC2 contains only SN Ia). We discuss how the distribution in redshift measured for the SN candidates changes according to the selected host galaxy and redshift estimate. Results.We measured the SN Ia rate, analyzing the impact of uncertainties due to photometric redshift, host-galaxy association and classification on the distribution in redshift of the starting sample. We find that we are missing 17% of the SN Ia, on average, with respect to the simulated sample. As 10% of the mismatch is due to the uncertainty on the photometric redshift alone (which also affects classification when used as a prior), we conclude that this parameter is the major source of uncertainty. We discuss possible reduction of the errors in the measurement of the SN Ia rate, including synergies with other surveys, which may help us to use the rate to discriminate different progenitor models.

Astronomy & Astrophysics↗

DOE OSTI2025

Defect Complexes in CrSBr Revealed Through Electron Microscopy and Deep Learning

Atomic defects underpin the properties of van der Waals materials, and their understanding is essential for advancing quantum and energy technologies. Scanning transmission electron microscopy is a powerful tool for defect identification in atomically thin materials, and extending it to multilayer and beam-sensitive materials would accelerate their exploration. Here, we establish a comprehensive defect library in a bilayer of the magnetic quasi-1D semiconductor CrSBr by combining atomic-resolution imaging, deep learning, and calculations. We apply a custom-developed machine learning work flow to detect, classify, and average point vacancy defects. This classification enables us to uncover several distinct Cr interstitial defect complexes, combined Cr and Br vacancy defect complexes, and lines of vacancy defects that extend over many unit cells. We show that their occurrence is in agreement with our computed structures and binding energy densities, reflecting the intriguing layer interlocked crystal structure of CrSBr. Our ab initio calculations show that the interstitial defect complexes give rise to highly localized electronic states. These states are of particular interest due to the reduced electronic dimensionality and magnetic properties of CrSBr and are, furthermore, predicted to be optically active. Our results broaden the scope of defect studies in challenging materials and reveal new defect types in bilayer CrSBr that can be extrapolated to the bulk and to over 20 materials belonging to the same FeOCl structural family.

deep learning↗

DOE OSTI2025

Chandra Discovery of a Candidate Hyperluminous X-Ray Source in MCG+11-11-032

We present a multiwavelength analysis of MCG+11-11-032, a nearby active galactic nucleus (AGN), with a unique classification as being both a binary and a dual AGN candidate. With new Chandra observations, we aim to resolve any dual AGN system via imaging data and search for signs of a binary AGN via analysis of the X-ray spectrum. Analyzing the Chandra spectrum, we find no evidence of the previously suggested double-peaked Fe Kα lines; the spectrum is instead best fit by an absorbed power law with a single Fe Kα line, as well as an additional line centered at ≈7.5 keV. The Chandra observation reveals faint, soft, and extended X-ray emission, possibly linked to low-level nuclear outflows. Further analysis shows evidence for a compact hard source—MCG+11-11-032 X2—located 3.″3 from the primary AGN. Modeling MCG+11-11-032 X2 as a compact source, we find that it is relatively luminous (L2–10 keV=1.5−0.5+0.9×1041erg s$^{−1}$), and the location is coincident with a compact and off-nuclear source resolved in Hubble Space Telescope infrared (F105W) and optical (F621M, F547M) bands. Pairing our X-ray results with a 144 MHz radio detection at the host galaxy location, we observe X-ray and radio properties similar to those of ESO 243-49 HLX-1, suggesting that MCG+11-11-032 X2 may be a hyperluminous X-ray source. This detection with Chandra highlights the importance of a high-resolution X-ray imager as well as how previous binary AGN candidates detected with large-aperture instruments can benefit from high-resolution follow-up. Future spatially resolved optical spectra, and deeper X-ray observations, can better constrain the origin of MCG+11-11-032 X2.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2025

Deploying Adversarial Attacks in Super-Resolution Models

Reliable super-resolution methods are crucial for applications like remote sensing, grid resilience and disaster impact analysis, and standoff biometrics. These methods infuse additional high-frequency information into reconstructions, allowing for better contextualization and image intelligence. However, super-resolution models can also introduce hallucinations or other unseen vulnerabilities that could be exploited by an adversary. This is further compounded by the prominence of deep learning in these models, as models are often blindly applied on out-of-distribution images. In this work, we implement adversarial attacks in common open-source super-resolution models and examine their impact on reconstructions and downstream classification tasks. We find that an adversarially trained super-resolution model can produce high-quality reconstructions that degrade downstream classifications. Moreover, these attacks do not require access to low-resolution imagery or class labels at inference time. These results demonstrate the vulnerability of super-resolution methods to malicious actors and motivates the development of a detector for super-resolution adversarial attacks. Further exploration of adversarial attacks in this domain is required to ensure trustworthiness and robustness of super-resolution models for national security applications.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2026

A machine learning pipeline for identifying infiltration managed aquifer recharge locations from satellite imagery in the San Joaquin Valley, California

This study focuses on an agricultural region in California’s Central Valley, USA, where Managed Aquifer Recharge (MAR) is widely implemented to mitigate groundwater depletion under increasing water demand and climate variability. A deep learning and machine learning framework was developed to identify infiltration-MAR locations using satellite imagery and environmental data. The framework integrates surface water detection from Sentinel-2 imagery, geospatial delineation of water bodies, spatiotemporal tracking of water body dynamics, and supervised classification using meteorological, environmental, and topographic variables. The framework was applied to a 2379 km² study area southwest of Fresno, where 765 water bodies were detected, including 139 identified MAR sites based on publicly available datasets and expert knowledge. The classification model achieved an accuracy of 0.94 and an F1 score of 0.85. Feature importance analysis indicates that cropland, normalized difference vegetation index (NDVI), and evaporation are among the most influential predictors for infiltration-MAR. Notably, the framework suggests that engineered water management in infiltration-MAR systems can disrupt or even reverse the expected positive correlation between surface water extent and precipitation. These findings provide physically interpretable insights into the characteristics of existing infiltration-MAR facilities and demonstrate the potential of the proposed framework as a reproducible, interpretable, and potentially transferable tool for data-driven infiltration-MAR identification and inventory development under growing climatic and hydrological uncertainty.

Classification↗

DOE OSTI2024

Unpaired image translation to mitigate domain shift in liquid argon time projection chamber detector responses

Deep learning algorithms often are developed and trained on a training dataset and deployed on test datasets. Any systematic difference between the training and a test dataset may severely degrade the final algorithm performance on the test dataset—what is known as the domain shift problem . This issue is prevalent in many scientific domains where algorithms are trained on simulated data but applied to real-world datasets. Typically, the domain shift problem is solved through various domain adaptation (DA) methods. However, these methods are often tailored for a specific downstream task, such as classification or semantic segmentation, and may not easily generalize to different tasks. This work explores the feasibility of using an alternative way to solve the domain shift problem that is not specific to any downstream algorithm. The proposed approach relies on modern Unpaired Image-to-Image (UI2I) translation techniques, designed to find translations between different image domains in a fully unsupervised fashion. In this study, the approach is applied to a domain shift problem commonly encountered in Liquid Argon Time Projection Chamber (LArTPC) detector research when seeking a way to translate samples between two differently distributed LArTPC detector datasets deterministically. This translation allows for mapping real-world data into the simulated data domain where the downstream algorithms can be run with much less domain-shift-related performance degradation. Conversely, using the translation from the simulated data to a real-world domain can increase the realism of the simulated dataset and reduce the magnitude of any systematic uncertainties. To evaluate the quality of the translations, we use both pixel-wise metrics and a downstream task to measure the effectiveness of UI2I methods for mitigating the domain shift problem. We adapted several popular UI2I translation algorithms to work on scientific data and demonstrated the viability of these techniques for solving the domain shift problem with LArTPC detector data. To facilitate further development of DA techniques for scientific datasets, the ‘Simple Liquid-Argon Track Samples’ dataset used in this study is also published.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Enhanced Machine-Learning Flow for Microwave-Sensing Systems for Contaminant Detection in Food

The presence of foreign bodies in packaged food is a serious concern for both fnal consumers (allergies, injuries, choking) and food manufacturers (reputation and economic losses). In particular, low-density plastics, glass and wood splinters are hard to detect even by the most advanced X-ray imagers. One solution is Machine-Learning-based Microwave Sensing (MLMWS): a non-invasive, contactless, and real-time method which uses a machine-learning (ML) classifer to analyze the scattered microwaves from the irradiated target object. In this paper, we want to extend our previous work about contaminant detection in cocoa-hazelnut spread jars by proposing an enhanced ML flow to increase the accuracy of the ML classifier. For the first time in this case study, we use a multi-class classifier, we train it with scattering parameters measured at multiple microwave frequencies, with a new pre-processing scaler, data augmentation, quantization-aware training and a pruning schedule. The results show a contaminant detection multi-class accuracy of 94.167% with a latency of 26 µs when targeting an AMD/Xilinx Kria K26 FPGA. Finally, we released our datasets publicly to OpenML.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗