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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Model-Agnostic Algorithm for Real-Time Attack Identification in Power Grid using Koopman Modes

Malicious activities on measurements from sensors like Phasor Measurement Units (PMUs) can mislead the control center operator into taking wrong control actions resulting in disruption of operation, financial losses, and equipment damage. In particular, false data attacks initiated during power systems transients caused due to abrupt changes in load and generation can fool the conventional model-based detection methods relying on thresholds comparison to trigger an anomaly. In this paper, we propose a Koopman mode decomposition (KMD) based algorithm to detect and identify false data attacks in real-time. The Koopman modes (KMs) are capable of capturing the nonlinear modes of oscillation in the transient dynamics of the power networks and reveal the spatial embedding of both natural and anomalous modes of oscillations in the sensor measurements. The Koopman-based spatio-temporal nonlinear modal analysis is used to filter out the false data injected by an attacker. The performance of the algorithm is illustrated on the IEEE 68-bus test system using synthetic attack scenarios generated on GridSTAGE, a recently developed multivariate spatio-temporal data generation framework for simulation of adversarial scenarios in cyber-physical power systems.

Nandanoori, Sai Pushpak↗
DOE OSTI2025

Templates for Risk Informed Assurance with Curvature Embeddings (TRACE)

We investigate recovery of geometric structure from networks embedded in manifolds with spatially varying curvature, extending the constant-curvature framework of Lubold et al. (2023). Our work supports cascade risk assessment in critical infrastructure through the Templates for Risk-informed Assurance with Curvature Embeddings (TRACE) framework. Simulations on a bi-modal Gaussian surface show that constant-curvature methods yield weighted averages shaped by clique patterns, while hierarchical clustering identifies distinct regimes. Localized estimation, however, reveals boundary contamination in transitional regions. To address heterogeneity, we develop distance metrics for graphs with edge and node features, proving their metric validity, and validate them via deterministic graph generation from canonical tilings. We further propose a diffusion-based anomaly detection approach that treats networks as glued manifolds, using curvature discontinuities to detect structural anomalies. Employing the carré-du-champ operator and scalar curvature, we achieve robust anomaly discrimination, demonstrated on the Singapore Water Treatment (SWaT) dataset with joint network-traffic and sensor features. Integration with TRACE reveals how curvature shapes cascade dynamics: positive curvature impedes, while negative curvature accelerates propagation. This geometric perspective provides interpretable risk metrics and visualization tools for critical infrastructure managers. While full validation remains ongoing, our contributions establish a rigorous foundation for geometric analysis of network resilience and cascade vulnerability.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Explainable machine learning for incipient anomaly detection in compact molten salt heat exchanger with overlapping feature distributions

High-temperature molten salt-cooled reactors (MSCRs) are a promising next-generation nuclear technology option, offering efficient power conversion and inherent safety features. However, the reliability of these systems depends on the robust operation of heat exchangers (HXs), which are susceptible to failure due to temperature gradients and channel plugging caused by fluid freezing. Conventional monitoring methods, relying on inlet and outlet measurements, lack the spatial resolution needed to detect early-stage faults. We propose a novel design of a compact salt-to-salt matrix-type HX design consisting of interleaved arrays of parallel tubes, with integrated synthetic fiber optic distributed temperature sensing (DTS) to enable localized detection of incipient faults. To evaluate performance of this design, we generate high-fidelity synthetic data using heat transfer computational modeling to simulate channel plugging, and introduce sensor noise for realistic modeling of measurements. The dataset comprises of 97% normal operation and 3% anomaly cases, with each anomaly class representing 1% of the data. These early anomalies result in overlapping temperature profiles between normal and faulty channels, producing a non-separable dataset that challenges traditional classification techniques. We benchmark eight supervised machine learning (ML) models and demonstrate that XGBoost achieves the highest performance. To improve transparency, we develop an explainability framework combining Shapley values and partially ordered sets (POSETs) to quantify and structurally analyze feature importance. This approach identifies both dominant predictors and ambiguous feature relationships, enhancing trust and interpretability. Our results highlight the potential of combining DTS and explainable ML with intelligent feature selection to improve predictive maintenance and ensure operational resilience in advanced nuclear systems.

Prantikos, Konstantinos [Argonne National Laborato↗
DOE OSTI2025

Non-destructive structural characterization of graphite components using mechanical resonance and deep learning

As compared to conventional nuclear reactors, microreactors have the potential to significantly reduce construction timelines and capital costs, decreasing the barriers for advanced nuclear reactor technologies. However, the lower power output of these microreactors (typically < 20 MWe) creates challenging economics if operation and maintenance costs cannot be sufficiently reduced. The compact size of these designs presents an opportunity for comprehensive in-situ structural health monitoring to provide real-time feedback in order to reduce operational costs associated with maintenance and downtime. Many microreactor concepts use graphite for both in-core neutron moderation and as a structural material, which has typically required some form of periodic and laborious inspection. This report provides a description and assessment of recent work with graphite to couple acoustic-based experimental measurements and characterization with machine learning models to mature structural health monitoring capabilities and generate benefits for the nuclear microreactor industry. With resilient embedded sensors in development in other programs funded by the US Department of Energy’s Office of Nuclear Energy and elsewhere, the work described herein builds upon previously funded efforts to mature non-destructive testing technology that relates measured vibrational signatures to structural changes, using a combination of new experimental measurements and machine learning processing. Building on past successful demonstrations of predictive workflows to identify structural changes in a hexagonal stainless steel test article with excellent acoustic propagation, we first performed baseline characterization on graphite samples with canonical geometries to ensure compatibility and confidence in the applied techniques for a material with distinctly different mechanical properties. In contrast to efforts in previous years, we worked exclusively with unidirectional vibration data that is more comparable to those expected from the existing embedded sensor technologies which are suitable for deployment in a reactor setting. Established acoustic and modern machine-learning-based characterization approaches were applied to the resulting datasets from these simple geometries. Both approaches were found to be highly capable of detecting even small geometric irregularities amongst nominally identical samples. As such, we then moved to testing these approaches for detection of artificial local stress perturbations introduced into a more complex geometry: a hexagonal block with drilled holes. A main outcome of this work is that a generalizable ML workflow can be used to detect and predict the characteristics of small artificial anomalies in a graphite component with a relevant geometry. While this work was performed using surficial vibration data, we expect the approach to be flexible and viable for other monitoring scenarios, such as those with different arrangements or types of sensor arrays. As compared to previously funded efforts, an existing ML workflow based on neural networks was enhanced through the addition of recently developed Fourier neural operators. As applied to previously collected and new vibration datasets, prediction accuracies of anomaly characterizations were greatly improved with minimal added computational cost. As trained on small durations of vibration data (tens of seconds) collected over a realistic number of locations, the model was able to reliably determine the presence of a subtle stress anomaly and begin to provide location estimates. Such an approach is likely to be viable for more relevant reactor damage scenarios for graphite components, such as progressive crack growth or creep.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Designing an Intrusion Proof Adjustable Speed Drive System Controlling a Critical Process

In this paper, an intrusion proof adjustable speed drive system controlling a critical process in an industrial control system is detailed. In such a system, should the motor speed sensor signal data be compromised and/or altered via a cyber-attack, the system can potentially be unregulated, over speed and/or malfunction thereby disrupting the critical process. The proposed active detection scheme detailed in this paper introduces a private (secret) random signal termed as "watermark" into the inverter control signal that determines the PWM gating signals of the DC-AC inverter powering the motor. The watermarking signal introduced into the PWM modulation for the DC-AC inverter is shown to propagates its unique signature, which appears in all sensors signals at the inverter output such as voltage/current/speed used to control the motor. Now employing the measured data (from sensors), two statistical variance tests are conducted to identify anomalies if any in the presence of the watermarking signal. It is shown when an intrusion occurs to manipulate the sensor data to disturb and/or destabilize the process, the proposed tests immediately display a high value indicating a compromise in sensor data. It is shown that the proposed system is capable of immediate detection of a sophisticated attacks such as record/reply attack in which the actual speed sensor is disconnected and a prerecorded speed signal from the past of the same magnitude is played back to the controller. Several types of cyber-attacks such as speed reduction/increase including vibration have been tested. Extensive simulation results verify the proposed concepts. Experimental results will be discussed in the conference presentation.

Alotaibi, Faris↗
DOE OSTI2020

FALCON: Framework for Anomaly Detection in Industrial Control Systems

Industrial Control Systems (ICS) are used to control physical processes in critical infrastructure. These systems are used in a wide variety of operations such as water treatment, power generation and distribution, and manufacturing. While the safety and security of these systems are of serious concern, recent reports have shown an increase in targeted attacks aimed at manipulating physical processes to cause catastrophic consequences. This trend emphasizes the need for algorithms and tools that provide resilient and smart attack detection mechanisms to protect ICS. In this paper, we propose an anomaly detection framework for ICS based on a deep neural network. The proposed methodology uses dilated convolution and long short-term memory (LSTM) layers to learn temporal as well as long term dependencies within sensor and actuator data in an ICS. The sensor/actuator data are passed through a unique feature engineering pipeline where wavelet transformation is applied to the sensor signals to extract features that are fed into the model. Additionally, this paper explores four variations of supervised deep learning models, as well as an unsupervised support vector machine (SVM) model for this problem. The proposed framework is validated on Secure Water Treatment testbed results. This framework detects more attacks in a shorter period of time than previously published methods.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2026

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

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

42 ENGINEERING↗
DOE OSTI2022

Bayesian Estimation of Oscillator Parameters: Toward Anomaly Detection and Cyber-Physical System Security

Cyber-physical system security presents unique challenges to conventional measurement science and technology. Anomaly detection in software-assisted physical systems, such as those employed in additive manufacturing or in DNA synthesis, is often hampered by the limited available parameter space of the underlying mechanism that is transducing the anomaly. As a result, the formulation of anomaly detection for such systems often leads to inverse or ill-posed problems, requiring statistical treatments. Here, we present Bayesian inference of unknown parameters associated with a generic actuator considered as a representative vital element of a cyber-physical system. Via a series of experimental input-output measurements, a transfer function for the actuator is obtained numerically, which serves as our model for the proposed method. Linear, nonlinear, and delayed dynamics may be assumed for the actuator response. By devising a code-based malicious signal, we study the efficacy of Bayesian inference for its potential to produce a detection, including uncertainty quantification, with a remarkably small number of input data points. Our approach should be adaptable to a variety of real-time cyber-physical anomaly detection scenarios.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Detection of False Data Injection Attacks in Battery Stacks Using Input Noise-Aware Nonlinear State Estimation and Cumulative Sum Algorithms

Grid-scale battery energy storage systems (BESSs) are vulnerable to false data injection attacks (FDIAs), which could be used to disrupt state of charge (SoC) estimation. Inaccurate SoC estimation has negative impacts on system availability, reliability, safety, and the cost of operation. In this article a combination of a Cumulative Sum (CUSUM) algorithm and an improved input noise-aware extended Kalman filter (INAEKF) is proposed for the detection and identification of FDIAs in the voltage and current sensors of a battery stack. The series-connected stack is represented by equivalent circuit models, the SoC is modeled with a charge reservoir model and the states are estimated using the INAEKF. Further, the root mean squared error of the states’ estimation by the modified INAEKF was found to be superior to the traditional EKF. By employing the INAEKF, this article addresses the research gap that many state estimators make asymmetrical assumptions about the noise corrupting the system. Additionally, the INAEKF estimates the input allowing for the identification of FDIA, which many alternative methods are unable to achieve. The proposed algorithm was able to detect attacks in the voltage and current sensors in 99.16% of test cases, with no false positives. Utilizing the INAEKF compared to the standard EKF allowed for the identification of FDIA in the input of the system in 98.43% of test cases.

25 ENERGY STORAGE↗
DOE OSTI2023

Background Adaptive Radiation Detection (BARD) v1.0.0

The Background Adaptive Radiation Software can be deployed with static sensors in urban environments. It provides a real-time robust radiation detection based on a unique adaptive learning approach. Local radiation background models are automatically learnt for various environmental conditions, and monitored/re-trained, and selected over time for optimal radiation anomaly detection, informed by source templates directly derived from the data.

Abgrall, Nicolas↗
DOE OSTI2025

Self-Supervised T-GCN for Detection of Disturbance and Propagation in Power Grid

Urban power systems increasingly rely on dense sensing to monitor grid reliability, yet disturbance labels are scarce and events are rare. We present a self-supervised spatio-temporal method that detects, localizes, and characterizes grid frequency disturbances across urban areas using only unlabeled data. Our approach trains a tiny Temporal Graph Convolutional Network (T-GCN) to forecast per-site frequency residuals (deviation from 60 Hz). The sensor graph is constructed directly from signals using pre-event Pearson correlation with a cross-correlation lag penalty without geocoding. At inference, node-level anomalies are the model's forecast errors; region-level alarms arise from connected components of high-score nodes. We estimate disturbance propagation by computing per-node arrival times (first persistent exceedance), then fit a planar or time-of-arrival model to obtain direction, speed, and an epicenter proxy. With only three real events collected at decisecond resolution across U.S. cities, we evaluate the T-GCN and report time-to-detect, footprint size, and propagation consistency. We further show that short-window embeddings from the T-GCN's hidden states enable few-shot event-vs-background recognition via a simple prototypical classifier. Despite minimal data and no labels, our system yields fast, spatially coherent detection and interpretable propagation maps, offering a practical, lightweight pathway to city-scale grid resilience analytics.

Niu, Haoran [ORNL] (ORCID:0000000155228297)↗
DOE OSTI2023

Application of Machine Learning to Monitor Metal Powder-Bed Fusion Additive Manufacturing Processes

The use of additive manufacturing (AM) is increasing for high-value, critical applications across a range of disparate industries. This article presents a discussion of high-valued engineering components predominantly used in the aerospace and medical industries. Applications involving metal AM, including methods to identify pores and voids in AM materials, are the focus. The article reviews flaw formation in laser-based powder-bed fusion, summarizes sensors used for in situ process monitoring, and outlines advances made with in situ process-monitoring data to detect AM process flaws. It reviews investigations of ML-based strategies, identifies challenges and research opportunities, and presents strategies for assessing anomaly detection performance.

Reutzel, Edward W.↗
DOE OSTI2024

System and method for in situ inspection of defects in additively manufactured parts using high speed melt pool pyrometry

A system and method is disclosed for detecting anomalies in an additively manufactured part. An energy source generates a signal forming an optical beam for creating a melt pool in a layer of feedstock material being selectively fused to make a part in an additive manufacturing operation. A sensor is configured to receive a signal reflected from the melt pool. The reflected signal forms a thermal signal indicative of a temperature of the feedstock material at a known location on a layer of the feedstock material while the feedstock material is being fused at the known location. A controller receives and analyzes data relating to the received signal to determine if an anomaly exists at the known location.

Forien, Jean-Baptiste↗
DOE OSTI2026

Rolling Root Mean Square Based Multimodal Anomaly Detection for Real Time Monitoring of Smart Grid

Reliable real-time monitoring is valuable for maintaining the operational integrity of modern electrical smart grids. Deployment of heterogeneous sensing technologies in substations has enabled high-resolution, multichannel waveform monitoring, but also introduces challenges for anomaly detection due to noise, baseline drift, and modality-dependent signal characteristics. In this work, we present a computationally efficient unsupervised method for multimodal event detection based on Rolling Root Mean Square based Event Detection (RRMSED). The method is developed using in-house, field deployed sensors collecting data at a utility substation. The sensing system comprises voltage and current sensors, triaxial accelerometers, and magnetometers, collectively capturing electrical, vibrational, and magnetic waveform measurements at high temporal resolution. RRMSED operates by extracting rolling RMS energy features and their first-order temporal differences from consecutive waveform segments for each channel and then applying channel-specific statistical thresholds learned from historical data. A persistence-based exceedance logic is employed to robustly identify transient events while suppressing impulsive noise, and to provide precise temporal localization with high resolution. The framework is designed for continuous server-side operation and can be deployed in real time without requiring complex models. Experiments on simulated waveform data with known ground truth demonstrate low false positive (FP) and false negative (FN) rates. Application to real substation data shows RRMSED to identify events that are not captured by conventional monitoring indicators including fast transient detection algorithm currently deployed in the system. These results indicate that rolling RMS based features provide an effective and practical basis for real-time multimodal event detection in smart-grid substations.

Mukherjee, Subrata [ORNL] (ORCID:0000000309930338)↗
DOE OSTI2020

Time-Lapse Gravity Monitoring of CO2 Migration Based on Numerical Modeling of a Faulted Storage Complex

In this study, the performance of both surface and borehole time-lapse gravity monitoring to detect CO2 leakage from a carbon storage site is evaluated. Several hypothetical scenarios of CO2 migration in a leaky fault, and thief zones at different depths at the Kimberlina site (California, USA) constitute the basis of the approach. The CO2 displacement is simulated using the TOUGH2 simulator applied to a detailed geological model of the site. The gravity responses to these CO2 plumes are simulated using forward modeling with sensors at ground surface and in vertical boreholes. Results of inversion on one scenario are also presented. The surface-based gravity responses obtained for the different leakage scenarios demonstrate that leakage can be detected at the surface in all the scenarios but the time to detection is highly variable (10 to 40 years) and dependent on the detection threshold considered. Borehole measurements of the vertical component of gravity provide excellent constrains in depth when they are located in proximity of the density anomaly associated with the presence of CO2, thus discriminating multiple leaks in different thief zones. Joint inversion of surface and borehole data can bring valuable information of the occurrence of leakages and their importance by providing a reasonable estimate of mass of displaced fluids. This study demonstrates the importance of combining multiphase flow simulations with gravity modeling in order to define if and when gravity monitoring would be applicable at a given storage site.

Time-lapse gravity monitoring, leak detection, CCS↗
DOE OSTI2021

Integration of Simulated and Real Distributed Acoustic Sensor Measurements to Develop AI Enhanced Intelligent Sensing Operations

Distributed acoustic sensors (DAS) have shown remarkable success in monitoring critical civil, energy and transportation assets over long distances and under harsh environmental conditions. Integration of artificial intelligence (AI) technologies with DAS can extend their operational capabilities from conventional tasks (e.g., vibration frequency detection) to more advanced intelligent tasks like anomaly detection. However, these AI technologies often require large labeled/ annotated DAS measurements datasets of the assets in both normal and anomalous operating conditions. This data acquisition task can be both time consuming and costly. This work develops a generative adversarial network based unsupervised domain adaptation framework to build intelligent DAS operational capabilities.

Venketeswaran, Abhishek↗
DOE OSTI2025

Real-Time Testbed for Studying Cyberattacks and Defense in DER-integrated Smart Inverter Systems

In this paper, we propose a Hardware-in-the-Loop (HIL) simulation testbed suitable for the implementation and testing of realistic cyberattacks on grid-tied smart inverter systems integrated with Distributed Energy Resources (DER) that use the Distributed Network Protocol-3 (DNP3) protocol for communications between grid components. Specifically, our testbed combines a Real-Time Digital Simulator (RTDS) NovaCor device, outfitted with GNETx2 network interface cards, a gridtied DER topology implemented via the RTDS software package RSCAD, and a custom virtual network that emulates a man in the middle attacker. The Man-in-the-Middle (MITM) attacker captures DNP3 traffic and falsifies telemetry data in DNP3 packets to trigger unwarranted commands from a DNP3 controller that exploit smart inverter grid support functions. We choose DNP3 and implement grid support functions according to the IEEE Std. 1547-2018 mandated for the interconnection and interoperability of DER power systems with associated power components. Furthermore, we develop a protocol payload agnostic attack detection framework that leverages the round-trip time (RTT) anomalies between DNP3 requests and responses and can detect the presence of attacks without having to analyze the payload’s contents, while balancing trade-offs between false alarm counts, missed detections, and time to detection. To facilitate further research, we publicly release benign and attack network traffic exchanged between various sensors, controllers, and actuators in our grid-tied inverter testbed.

24 POWER TRANSMISSION AND DISTRIBUTION↗