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Constrained GAN-Generated X-Ray CT Data For Self-Supervised And Foundation-Model Segmentation Of Concrete Microstructures

Three-dimensional characterization of materials using X-ray computed tomography (XCT) is challenging due to the complexity of internal structures, noise, and variations in resolution. Traditional computer vision models often struggle to accurately segment these images, particularly in domain-specific applications like materials science. While supervised deep learning approaches have been developed to address the limitations of conventional algorithms, they typically require large amounts of labeled training data and often fail to generalize across different datasets. Self-supervised, few-and zero-shot learning methods have gained prominence in natural image processing and segmentation tasks, but their application to scientific imaging remains limited due to the unique structural complexity, noise, and textural artifacts present in materials science data. In this work, we investigate how domain adaptation, leveraging physics-based and GAN-generated synthetic data, impacts segmentation performance. We introduce a modified Contrastive Unpaired Translation (CUT) model designed to generate realistic labeled data, which can be used for training, pre-training, and fine-tuning segmentation models for real XCT microstructure data. We evaluate the performance of two segmentation approaches: a self-supervised network (SSL-ALPNet) and a foundation model (Segment Anything Model), assessing their improvements when pre-trained and/or fine-tuned on the synthesized data. Our results demonstrate that leveraging synthetic data significantly enhances segmentation performance, particularly in challenging materials science applications.

Ziabari, Amir [ORNL] (ORCID:000000034776457X)

Foundation Models for Zero-Shot Segmentation of Scientific Images without AI-Ready Data

Zero-shot and prompt-based models have excelled at visual reasoning tasks by leveraging large-scale natural image corpora, but they often fail on sparse and domain-specific scientific image data. We introduce Zenesis, a no-code interactive computer vision platform designed to reduce data readiness bottlenecks in scientific imaging workflows. Zenesis integrates lightweight multimodal adaptation for zero-shot inference on raw scientific data, human-in-the-loop refinement, and heuristic-based temporal enhancement. We validate our approach on Focused Ion Beam Scanning Electron Microscopy (FIB-SEM) datasets of catalyst-loaded membranes. Zenesis outperforms baselines, achieving an average accuracy of 0.947, Intersection over Union (IoU) of 0.858, and Dice score of 0.923 on amorphous catalyst samples; and 0.987 accuracy, 0.857 IoU, and 0.923 Dice on crystalline samples. These results represent a significant performance gain over conventional methods such as Otsu thresholding and standalone models like the Segment Anything Model (SAM). Zenesis enables effective image segmentation in domains where annotated datasets are limited, offering a scalable solution for scientific discovery.

Mukherjee, Shubhabrata

SAM-I-Am: Semantic boosting for zero-shot atomic-scale electron micrograph segmentation

Image segmentation is a critical enabler for tasks ranging from medical diagnostics to autonomous driving. However, the correct segmentation semantics — where are boundaries located? what segments are logically similar? — change depending on the domain, such that state-of-the-art foundation models can generate meaningless and incorrect results. Moreover, in certain domains, fine-tuning and retraining techniques are infeasible: obtaining labels is costly and time-consuming; domain images (micrographs) can be exponentially diverse; and data sharing (for third-party retraining) is restricted. To enable rapid adaptation of the best segmentation technology, we propose the concept of semantic boosting: given a zero-shot foundation model, guide its segmentation and adjust results to match domain expectations. Here, we apply semantic boosting to the Segment Anything Model (SAM) to obtain microstructure segmentation for transmission electron microscopy. Our booster, SAM-I-Am, serves as a post-processing engine that extracts geometric and textural features of various intermediate masks to perform mask removal and mask merging operations. We demonstrate a zero-shot performance increase of (absolute) +21.35%, +12.6%, +5.27% in mean IoU, and a -9.91%, -18.42%, -4.06% drop in mean false positive masks across images of three difficulty classes over vanilla SAM (ViT-L).

36 MATERIALS SCIENCE

pnnl/SAMIAm

We apply semantic boosting to the Segment Anything Model (SAM) to obtain microstructure segmentation for transmission electron microscopy. Our booster, SAM-I-Am, extracts geometric and textural features of various intermediate masks to perform mask removal and mask merging operations

Mesfin, Waqwoya

Patch-Based Convolutional Neural Networks for Multiple Microstructural Features Detection in FIB-SEM Micrographs of Irradiated Nuclear Fuel

Focused ion beam scanning electron microscopy (FIB-SEM) tomography has increasingly been utilized for acquiring three-dimensional (3D) microstructure features at the sub-micron scale in irradiated nuclear materials. This technique involves sequential ion beam slicing followed by electron beam imaging and compositional mapping using energy dispersive spectroscopy (EDS). Despite its growing use, several challenges persist. These include the time-intensive nature of data collection of EDS data, difficulties in distinguishing between various microstructures, and issues with image alignment. These challenges currently limit the broader application of FIB-SEM tomography in the field. To overcome these limitations, we propose using convolutional neural networks (CNNs) to automate microstructure identification in SEM images. Our study introduces a new framework for identifying microstructures in irradiated U-10Zr (wt. %) metallic fuel with limited annotated data. The framework includes the creation of a reliable annotated dataset with paired SEM and ground truth data from EDS maps, the applications of CNNs for microstructure identification, and the validation of model performance. Specifically, we employed the Segment Anything Model (SAM) to align SEM images with corresponding EDS maps and focused ion beam (FIB) tomography SEM data. We evaluate several models, including Patch-based U-Net, Attention U-Net, and Residual U-Net, finding that patch-based U-Net exhibits superior segmentation performance and consistency. This approach reduces reliance on EDS detectors and aids in accelerating nuclear material analysis process, highlighting the potential of advanced deep learning techniques to improve microstructural understanding in nuclear material. This is the first framework to integrate SAM and Patch-based CNN models for semantic segmentation of irradiated nuclear materials, with potential applicability to other tomography datasets.

36 - MATERIALS SCIENCE

Active Learning Meets Foundation Models: Fast Remote Sensing Data Annotation for Object Detection

Object detection in remote sensing demands extensive, high-quality annotations—a process that is both labor-intensive and time-consuming. In this work, we introduce a real-time active learning and semi-automated labeling framework that leverages foundation models to streamline dataset annotation for object detection in remote sensing imagery. For example, by integrating a Segment Anything Model (SAM), our approach generates mask-based bounding boxes that serve as the basis for dual sampling: (a) uncertainty estimation to pinpoint challenging samples, and (b) diversity assessment to ensure broad data coverage. Furthermore, our Dynamic Box Switching Module (DBS) addresses the well-known cold start problem for object detection models by replacing its suboptimal initial predictions with SAM-derived masks, thereby enhancing early-stage localization accuracy. Extensive evaluations on multiple remote sensing datasets plus a real-world user study, demonstrate that our framework not only reduces annotation effort, but also significantly boosts detection performance compared to traditional active learning sampling methods. The code for training and the user interface will be made available.

Burges, Marvin [ORNL] (ORCID:0000000312690769)

Uncertainty quantification of fireball features extracted from nuclear test films using computer vision

Films from the US’s historic nuclear testing era comprise the only extensive collection of imagery depicting high-yield detonations. These films offer unique insights into the characteristics of flows occurring on scales that are difficult to replicate experimentally, and they are a valuable source of data for the validation of models used to describe nuclear detonations. In recent work, we implemented modern computer vision and machine learning techniques to extract features of the fireball following nuclear detonation. With a training dataset of fireball films, we fine-tuned a You Only Look Once 11 (YOLO11) model to detect and track the fireball. Applied to a video, the outer bounding box produced in each frame by YOLO11 is used as an input prompt to Meta’s Segment Anything Model 2 (SAM2), which is shown to accurately predict the boundary of the fireball over time with high resolution. These state-of-the-art computer vision foundation models exhibit impressive visual accuracy in their results but lack an output of values that robustly quantify uncertainty in scientific applications. In this paper, we develop procedures for uncertainty quantification of extracted fireball features. We outline the application of a parallel attention mechanism to calculate uncertainty ranges that complement and better pose model validation data. This higher quality fireball validation data may serve to improve prognostic models describing nuclear detonations in support of nuclear forensic and emergency response activities.

Khristy, Joel [ORNL] (ORCID:0000000209963060)

YOLO11 to SAM2 pipeline for feature extraction from nuclear test films

The response to the effects of nuclear detonations is supported by models that describe the evolution of the nuclear fireball and cloud and the associated transport of active debris. Validation of those descriptions relies on data from the nuclear test operations. Video records of those events offer a rich source of information that was exploited to a limited extent in historic analyses. Computer vision and machine learning techniques are powerful tools that can be used to increase the number of measurements that can be obtained from those films. In this work, we apply computer vision techniques to automatically track the temporal evolution of the nuclear fireball. In particular, we apply You Only Look Once 11 (YOLO11) and Segment Anything Model 2 (SAM2) in combination with minimal human intervention to digitized versions of the original nuclear test films. As part of the proposed workflow, the YOLO11 model is applied to films to determine bounding boxes for the fireball within each frame. These are then used as inputs to SAM2, which uses image segmentation to determine the fireball boundaries and their temporal evolution. We assess the accuracy of our approach by using it to determine the energy released during the Trinity nuclear test and comparing the results with previous analyses based on manual measurements.

Van Exel, Kimberly [ORNL] (ORCID:0009000877463894)

Crack Identification and Characterization in Deformed Nb3Sn Rutherford Cable Stacks Using Machine Learning

An investigation of instance segmentation of cracks in Nb3Sn 4-stack 40-strand Rutherford cables using machine learning is presented. Three samples were uniaxially and biaxially loaded before metallographic inspections were performed. The Mask R-CNN model was used in the Detectron2 framework with pre-trained weights but fine-tuned to detect and segment cracks. The model detected cracks with bounding box and mask average precisions (AP) of 42.8 and 27.9, respectively, and was used for instance segmentation of all cracks in the three samples. More cracks were found in the sample pre-loaded along the z-axis (i.e., along the cable length). Pre-loading along the x-axis (i.e., on the cables edges) reduced the number of cracks and changed the crack orientation distribution, away from being highly aligned with the y-axis (i.e., normal to the cables broad faces), i.e., the direction with the highest applied load. Fine-tuning of the Segment Anything Model (SAM) was also studied but performed poorly without human-provided prompts. However, the zero-shot capability of SAM showed high promises to accelerate the image annotation process for applications beyond this study.

Croteau, Jean-Francois

pnnl/SuperSAM

Our SuperSAM approach transforms the Segment Anything Model (SAM) into an `elastic' supernetwork, enabling the derivation of subnetworks with varying architectures tailored to a wide range of resource constraints.

Tallent, Nathan