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At least 145 records · Page 8

Computational models of direct and indirect X‐ray breast imaging detectors for in silico trials

Abstract Background To facilitate in silico studies that investigate digital mammography (DM) and breast tomosynthesis (DBT), models replicating the variety in imaging performance of the DM and DBT systems, observed across manufacturers are needed. Purpose The main purpose of this work is to develop generic physics models for direct and indirect detector technology used in commercially available systems, with the goal of making them available open source to manufacturers to further tweak and develop the exact in silico replicas of their systems. Methods We recently reported on an in silico version of the SIEMENS Mammomat Inspiration DM/DBT system using an open‐source GPU‐accelerated Monte Carlo x‐ray imaging simulation code (MC‐GPU). We build on the previous version of the MC‐GPU codes to mimic the imaging performances of two other Food and Drug Administration (FDA)‐approved DM/DBT systems, such as Hologic Selenia Dimensions (HSD) and the General Electric Senographe Pristina (GSP) systems. In this work, we developed a hybrid technique to model the optical spread and signal crosstalk observed in the GSP and HSD systems. MC simulations are used to track each x‐ray photon till its first interaction within the x‐ray detector. On the other hand, the signal spread in the x‐ray detectors is modeled using previously developed analytical equations. This approach allows us to preserve the modeling accuracy offered by MC methods in the patient body, while speeding up secondary carrier transport (either electron–hole pairs or optical photons) using analytical equations in the detector. The analytical optical spread model for the indirect detector includes the depth‐dependent spread and collection of optical photons and relies on a pre‐computed set of point response functions that describe the optical spread as a function of depth. To understand the capabilities of the computational x‐ray detector models, we compared image quality metrics like modulation transfer function (MTF), normalized noise power spectrum (NNPS), and detective quantum efficiency (DQE), simulated with our models against measured data. Please note that the purpose of these comparisons with measured data would be to gauge if the model developed as part of this work could replicate commercially used direct and indirect technology in general and not to achieve perfect fits with measured data. Results We found that the simulated image quality metrics such as MTF, NNPS, and DQE were in reasonable agreement with experimental data. To demonstrate the imaging performance of the three DM/DBT systems, we integrated the detector models with the VICTRE pipeline and simulated DM images of a fatty breast model containing a spiculated mass and a calcium oxalate cluster. In general, we found that the images generated using the indirect model appeared more blurred with a different noise texture and contrast as compared to the systems with direct detectors. Conclusions We have presented computational models of three commercially available FDA‐approved DM/DBT systems, which implement both direct and indirect detector technology. The updated versions of the MC‐GPU codes that can be used to replicate three systems are available in open source format through GitHub.

Sengupta, Aunnasha↗

Review of capture cross sections relevant for intentional nuclear forensics

The NA-22 Intentional Forensics Venture is developing a system for tagging nuclear fuel using various methods of information encoding. One of the main methods under development is the insertion of isotopically enriched tracers into the fuel. In order to aid in the understanding of the neutronic performance of these taggants, we assess the quality of the nuclear data underpinning simulations, which are driven by the neutron-capture cross sections. We present these cross sections of naturally occurring isotopes of the elements provided in the neutron sublibrary of the planned ENDF/B-VIII.1 Feb. 2023 library release. We make this assessment using a rubric designed for this effort, which quantifies orthogonal features related to the overall quality. The quality metric highlights 6 aspects: experimental data, resonance evaluations, integral metrics, covariances, fission products, and documentation. We focus on energy ranges relevant for reactor applications. We also discuss additional sources for new, high-quality cross-section data that may be utilized on the time scale of the venture, including existing global data, new experiments, and computational methods. Finally, overall outlook is presented with conclusions.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Towards Generalizable and Efficient Circuit Topology Design: A Graph-Transformer-based Surrogate Model with Curriculum Learning

Unlike circuit parameter and sizing optimizations, the automated design of analog circuit topologies poses significant challenges for learning-based approaches. One challenge arises from the combinatorial growth of the topology space with circuit size, which limits the topology optimization efficiency. Moreover, traditional circuit evaluation methods are time-consuming, while the presence of data discontinuity in the topology space makes the accurate prediction of circuit performance exceptionally difficult for unseen topologies. To tackle these challenges, we design a novel Graph-Transformer-based Network (GTN) as the surrogate model for circuit evaluation, offering a substantial acceleration in the speed of circuit topology optimization without sacrificing performance. Our GTN model architecture is designed to embed voltage changes in circuit loops and current flows in connected devices, enabling accurate performance predictions for circuits with unseen topologies. To address the cold start problem when scaling GTN to large-scale circuits, we further introduce a curriculum learning strategy that progressively trains GTN from small-scale to large-scale circuits. This approach enables the model to first learn fundamental physical principles from simpler topologies and gradually adapt to complex configurations, effectively bridging the circuit complexity gap and improving prediction accuracy. Taking the power converter circuit design as an experimental task, our GTN model significantly outperforms an analytical approach and baseline methods directly utilizing graph neural networks. Furthermore, GTN achieves less than 5% relative error and 196× speed-up compared with high-fidelity simulation. Notably, our GTN surrogate model empowers an automatic circuit design framework to discover circuits of comparable quality to those identified through high-fidelity simulation while reducing the time required by up to 98.2%. With curriculum learning, the enhanced GTN achieves a 51% improvement for performance prediction of large-scale circuits compared to the GTN model without this strategy. These advancements establish GTN as a scalable framework for automated analog circuit design across varying circuit complexity levels.

Lu, Haoshu [New Jersey Institute of Technology (NJ↗

Assessing the Impact of Lightning NOx Emissions in CMAQ Using Lightning Flash Data from WWLLN over the Contiguous United States

Comparison of lightning flash data from the National Lightning Detection Network (NLDN) and from the World Wide Lightning Location Network (WWLLN) over the contiguous United States (CONUS) for the 2016–2018 period reveals temporally and spatially varying flash rates that would influence lightning NO x (LNO x ) production due to known detection efficiency differences especially during summer months over land (versus over ocean). However, the lightning flash density differences between the two networks show persistent seasonal patterns over geographical regions (e.g., land versus ocean). Since the NLDN data are considered to have higher accuracy (lightning detection with >95% efficiency), we developed scaling factors for the WWLLN flash data based on the ratios of WWLLN to NLDN flash data over time (months of year) and space. In this study, sensitivity simulations using the Community Multiscale Air Quality (CMAQ) model are performed utilizing the original data sets (both NLDN and WWLLN) and the scaled WWLLN flash data for LNO x production over the CONUS. The model performance of using the different lightning flash datasets for ambient O 3 and NO x mixing ratios that are directly impacted by LNO x emissions and the wet and dry deposition of oxidized nitrogen species that are indirectly impacted by LNO x emissions is assessed based on comparisons with ground-based observations, vertical profile measurements, and satellite products. During summer months, the original WWLLN data produced less LNO x emissions (due to its lower lightning detection efficiency) compared to the NLDN data, which resulted in less improvement in model performance than the simulation using NLDN data as compared to the simulation without any LNO x emissions. However, the scaled WWLLN data produced LNO x estimates and model performance comparable with the NLDN data, suggesting that scaled WWLLN may be used as a substitute for the NLDN data to provide LNO x estimates in air quality models when the NLDN data are not available (e.g., due to prohibitive cost or lack of spatial coverage).

54 ENVIRONMENTAL SCIENCES↗

Development of Large Scale Extrusion Deposition for Structural Applications

Large Scale Extrusion Deposition (LSED) is an evolving additive manufacturing (AM) technology that research, such as that taking place at Oak Ridge National Laboratory (ORNL) and companies like Local Motors, are continuing to utilize and develop new applications. A major LSED application of interest has been molds and tooling as it allows for much shorter production time and lower cost. However, interest has been expanding into using LSED for more structural applications due to more frequent use of high performing polymer composites as feedstock. The use of LSED for structural applications is of particular interest to Local Motors as it is currently being used to create commercially viable, energy efficient electric vehicles. LSED offers a unique opportunity when compared to traditional manufacturing methods as it can significantly reduce the number of components necessary, while decreasing embodied energy and carbon emissions. Even with these benefits however, it is important that LSED is properly understood from a structural aspect as this field has not been as heavily researched as tooling. To ensure a high level of safety and repeatability is an essential responsibility of a manufacturer whose products are structural in nature. As such it is important to understand the materials and LSED process to make structural objects that the manufacturer can be confident in. The main goals of this project were to: develop and investigate materials that are of interest for structural LSED applications, further develop and understand the current machines used in LSED and develop simulations tools of LSED and the mechanical properties of the created structure. Material development focused on composite materials that have high mechanical properties and are stable in a variety of environments. The materials were tested to determine their as printed mechanical and thermal properties as these are necessary for simulations. Once the materials were investigated thoroughly, it allowed for simulations to be performed to compare to experimental data with simulations. Materials were also vetted to determine candidates for multi-material printing. The machine development focused around the areas of process monitoring, non-destructive evaluation, and quality control. Finally, the goal of the simulations was to develop a realistic model of printed structures, including in-process simulation and dynamic simulation. The routes to get to some of these goals and the depth in which they were investigated changed throughout the project due to personnel changes and the COVID-19 pandemic. This project resulted in many valuable results such as the development of an nondestructive evaluation (NDE) technique for interlayer defects, proof of simulation for warpage in simple parts, the development and utilization of a profilometer to monitor a print for defects or inconsistencies, thorough investigation of a material used commercially for structural LSED applications and valuable experimental data on the applicability and advantages of multi-material crush structures versus their neat counterparts by creation and testing of samples.

36 MATERIALS SCIENCE↗

RectifHydPlus: Forty Year Hydropower Generation Reanalysis for Conterminous United States, Version 1.1.

This dataset contains monthly hydropower net-generation totals for 590 plants (each >10 MW) across the conterminous United States (CONUS) from 1980 to 2019. RectifHydPlus v1.1 includes one harmonized table of historical monthly generation—backfilled with observed monthly values where available—and two companion tables: (i) an estimates-only version with no backfill and (ii) a hydrological-control version that removes the effects of capacity and operational change. Each table comprises 23,600 records (590 plants × 40 years). The dataset was developed to address temporal gaps and inconsistencies in publicly available hydropower generation data as available through EIA-923 survey reports. Each record includes a quality label denoting the underlying proxy—from best (direct reservoir releases) to weakest (pattern copied from similar years). By combining the agency-reported survey records with observed and simulated hydrologic releases, RectifHydPlus offers complete, quality-labeled monthly estimates suitable for trend analysis and generation of hydropower generation inputs for energy-water modeling.

Turner, Sean [Oak Ridge National Laboratory (ORNL)↗

Secondhand Exposure to Simulated Cannabis Vaping Aerosols

Emissions from cannabis vaping degrade indoor air quality and expose non-users to secondhand pollutants. We investigated how the vaping mixture composition affects indoor aerosol characteristics and exposures. Simulated cannabis vaping aerosol was produced by flash evaporation in a 20 m3 chamber of mixtures containing terpenoids, cannabinoids, cannabis extract constituents, and the adulterant vitamin E acetate (VEA). Aerosol time- and size-resolved concentrations (8 nm-2.5 μm at 1 Hz) were measured, and a dosimetry model was used to evaluate the intake of secondhand aerosols. The results showed peak particle number (PN) concentrations between 0.7 × 106 and 13 × 106 cm-3 and peak mass concentration (PM1.0) between 65 and 1191 μg m-3 at t = 5 min after emission. Concentrations decreased to 21-57% of peak PN and 33-69% of peak PM1.0 at t = 60 min. The PM1.0 yield was 0.06 for a terpenoid-only mixture, 0.22-0.36 for tetrahydrocannabinol (THC)-terpenoid mixtures, and >1 for mixtures containing high concentrations of cannabidiol (CBD) or VEA. For intake deposition, the highest aerosol fraction was deposited in the pulmonary region, followed by the tracheobronchial and head regions. Deposition increased in the presence of THC, CBD, or VEA, with aerosols <100 nm contributing the majority of particles deposited in all regions.

Tang, Xiaochen↗

Using AI for Wave-front Estimation with the Rubin Observatory Active Optics System

Abstract The Vera C. Rubin Observatory will, over a period of 10 yr, repeatedly survey the southern sky. To ensure that images generated by Rubin meet the quality requirements for precision science, the observatory will use an active-optics system (AOS) to correct for alignment and mirror surface perturbations introduced by gravity and temperature gradients in the optical system. To accomplish this, Rubin will use out-of-focus images from sensors located at the edge of the focal plane to learn and correct for perturbations to the wave front. We have designed and integrated a deep-learning (DL) model for wave-front estimation into the AOS pipeline. In this paper, we compare the performance of this DL approach to Rubin’s baseline algorithm when applied to images from two different simulations of the Rubin optical system. We show the DL approach is faster and more accurate, achieving the atmospheric error floor both for high-quality images and low-quality images with heavy blending and vignetting. Compared to the baseline algorithm, the DL model is 40× faster, the median error 2× better under ideal conditions, 5× better in the presence of vignetting by the Rubin camera, and 14× better in the presence of blending in crowded fields. In addition, the DL model surpasses the required optical quality in simulations of the AOS closed loop. This system promises to increase the survey area useful for precision science by up to 8%. We discuss how this system might be deployed when commissioning and operating Rubin.

79 ASTRONOMY AND ASTROPHYSICS↗

Data-Driven Simulation-Based Planning for Electric Airport Shuttle Systems: A Real-World Case Study

Many airports are adopting battery electric buses in their shuttle fleets due to concerns over air quality and regulations. This study proposes a simulation-based optimization modeling framework to help airport shuttle operators effectively deploy electric buses. We evaluated a planned airport electric shuttle system with an event-driven simulator. Empirical data collected from existing systems were used to drive the simulations. We then proposed a simulation-based optimization model to determine the battery capacity, charging power, and number of chargers so that predefined objective(s) (e.g., minimizing total capital cost, minimizing emissions) are optimized. Compared to existing studies, the primary contribution of the proposed method is that it can model the real-world stochastic nature of operations in an electric bus system with much higher fidelity. To demonstrate the proposed modeling framework, we study a real-world shuttle system at the Dallas-Fort Worth International Airport, and present extensive numerical studies. When considering partial fleet electrification, the model can provide a set of Pareto optimal solutions. When considering full fleet electrification, the optimal solution requires a 50-kWh battery capacity and four 210-kW chargers, resulting in a total capital cost of $26,744,000. The results demonstrate that the proposed modeling framework can effectively optimize the planning of electric airport shuttle systems with partial or full fleet electrification.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗

Discrete Element Method Analysis for Metal Powders Used in Additive Manufacturing, and DEM Simulation Tutorial Using LIGGGHTS-PUBLIC [PowerPoint and paper]

Discrete Element Method (DEM) is a method of analysis to evaluate the dynamic interactions between granular particles. This method has been used in the pharmaceutical industry to improve the powder compaction process for tablet manufacturing. There are also applications in agriculture, food industry, and manufacturing. Direct energy deposition is an additive manufacturing technique which uses metallic powders fed through a nozzle, melted using a directed laser, and transformed into a solid object layer by layer. One way of feeding metal particles into the system involves the use of a vibrating hopper. Given a specified amplitude and frequency input, the hopper will enable the powder to travel up a path, and inject through the system with assistance from a stream of gas. The mechanical properties of a printed object can vary, depending on the characteristics of the powder flow and the particles’ as-received properties. Improved understanding of dynamic interactions of flowing powders could enable additive manufacturing components with 2D or 3D variations in mechanical properties, e.g., density. This work uses DEM simulation software to investigate the effects of particle cohesion, friction, and density on the quality of the flow by performing an angle of repose simulation, which is often used as a metric to evaluate the flowability of powders.

36 MATERIALS SCIENCE↗

Using FLAC{sup R} Modeling Software to Analyze the Stability of a LLRW Disposal Facility - 20031

Waste Control Specialists (WCS) wished to amend its existing LLRW disposal license such that it might use gravel aggregate instead of concrete as backfill around large component (LC) parts from decommissioned nuclear reactors. A classical mechanics evaluation of the strength of the LCs was presented to the Texas Commission on Environmental Quality (TCEQ), demonstrating that the LCs had adequate capacity to withstand the loads within the facilities, and that concrete was unnecessary for structural support. TCEQ requested that additional analyses of the LCs within the facilities be performed using FLAC{sup R} finite difference modeling software. Because FLAC{sup R} has the capability of modeling the support provided by the lateral earth pressures, the factors of safety against failure for the LCs increased. TCEQ found the FLAC{sup R} analyses presented in this report to be satisfactory, and granted WCS' license amendment request. This work demonstrates that FLAC{sup R} may be used advantageously to more accurately represent the complexities of the physical situation being modeled. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Energy impact of human health and wellness lighting recommendations for office and classroom applications

The goal of this investigation was to evaluate potential energy impacts of circadian lighting design recommendations gaining attention in a variety of common applications such as offices and classrooms. The renewed focus on health along with advances in SSL technology capabilities has underscored that there is still much to learn regarding the relationship between light and human physiology. The energy implications of designing to address these possible physiological effects are not yet fully understood. Beyond the fact that the basic metric of luminous efficacy (lumens per watt) does not cover these other effects, the emerging science seems to indicate that addressing a holistic view of the human needs in most applications may mean a need for increased light and associated energy use by electric lighting systems. Within the two applications considered, lumen output, spectral characteristics, surface reflectance distribution and desk orientation were varied to explore the magnitude of potential effects. Meeting current IES illuminance recommendations did not satisfy existing EML and CS recommendations for any of the simulations. In some cases, satisfying circadian metric recommendations required average illuminance that was more than double IES recommendations, which may negatively impact lighting quality as well. Using results from 45 unique simulation conditions, it was estimated that lighting energy use may increase between 10% and 100% due to increased luminaire light levels used to meet circadian lighting design recommendations listed in current building standards such as WELL v2 Q2 2019, UL Design Guideline 24480, and CHPS Core Criteria 3.0.

circadian lighting, lighting simulation, solid sta↗

Examination of synthetic gas puff imaging diagnostic data from a gyrokinetic turbulence code

A synthetic gas puff imaging (GPI) diagnostic has been developed for the purpose of validating the three-dimensional gyrokinetic turbulence code XGC. The synthetic diagnostic is described and applied to XGC simulations of two Alcator C-Mod discharges. The turbulence characteristics deduced from the resulting simulated GPI frames, using analysis techniques similar to those applied to experimental data, are compared with locally derived characteristics extracted directly from the XGC output. The comparison of the two is shown to be potentially impacted by misalignment between the GPI view and the magnetic field, the dependence of the light emission on the electron density and temperature, and spatial and temporal variations in the neutral gas cloud induced by the turbulent plasma fluctuations. We conclude that quantitative and, in some cases even qualitative, validation of turbulence simulations need to account for these effects. While we cannot directly compare our results with experimental data due to the absence of high quality GPI data from the shots and times simulated by XGC, we do relate the overall characteristics obtained from the synthetic GPI analysis to published Alcator C-Mod GPI data.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Increased nitrogen use efficiency in crop production can provide economic and environmental benefits

Potential economic and environmental benefits of increasing nitrogen-use efficiency (NUE) are widely recognized but scarcely quantified. This study quantifies the effects of increased NUE on 1) the national agricultural economy using a simulation model of US agriculture and 2) regional water quality effects using a biogeochemical model for the Arkansas-White-Red river basin. Here, national economic effects are reported for NUE improvement scenarios of 10%, 20%, 50%, and 100%, whereas regional water quality effects are estimated for a 20% NUE improvement scenario in the Arkansas-White-Red river basin. Simulating a 20% increase in NUE in row crops is shown to reduce N requirements by 1.4 million tonnes y-1 and increase farmer net profits by 1.6% ($743 million) per year by 2026 over the baseline simulation for the same period. For each 10% increase in NUE, annual farm revenues for commodity crops increased over the baseline by approximately $350 million per year by 2026. Changes in crop prices and land-use relative to the baseline were less than 2%. This suggests a net benefit even though fertilizer cost savings can result in increased cultivation of land, i.e., ‘Jevon's paradox’. Results from the biogeochemical model of the Arkansas-White-Red river basin suggest that a 20% increase in NUE corresponds to a 5.72% reduction in nitrate loadings to freshwaters, with higher reductions in agricultural watersheds. The value of these reductions was estimated as $43 ha-1, for a total of $15.3 to 136.7 million yr-1 in avoided water treatment costs. After estimating the social value of increased NUE, we conclude with a discussion of potential strategies to increase efficiency and the research needed to achieve this goal. These include perennialization of the agricultural landscape, genetic crop improvement, targeted fertilizer application, and manipulation of the plant-root microbiome.

54 ENVIRONMENTAL SCIENCES↗

NEML2: An efficient and modular multiphysics constitutive modeling library for hybrid computing environments

This paper presents NEML2, an open-source, high-performance library developed for constitutive material modeling, designed to support the flexible and modular development of models for complex material behavior. Building on the foundational structure of its predecessor, NEML, the NEML2 library introduces significant improvements, including enhanced vectorization, automatic differentiation, and seamless integration with PyTorch, facilitating the application of machine learning techniques in material simulations. NEML2 provides a C++ backend with Python bindings, enabling users to create custom material models that can be executed efficiently on both CPU and GPU platforms. The library also supports coupling with Multiphysics simulation frameworks like MOOSE, making it suitable for realistic simulations involving coupled physical processes. Rigorous quality assurance through unit and regression testing ensures the reliability of results, while the extensible, user-friendly design encourages collaboration and reproducibility across the scientific community. This paper provides an overview of NEML2’s architecture, core features, and applications, highlighting its impact on accelerating material qualification and advancing computational methods in materials science.

GPU↗

Deep Learning Analysis of Polaritonic Wave Images

Deep learning (DL) is an emerging analysis tool across the sciences and engineering. Encouraged by the successes of DL in revealing quantitative trends in massive imaging data, we applied this approach to nanoscale deeply subdiffractional images of propagating polaritonic waves in complex materials. Utilizing the convolutional neural network (CNN), we developed a practical protocol for the rapid regression of images that quantifies the wavelength and the quality factor of polaritonic waves. Using simulated near-field images as training data, the CNN can be made to simultaneously extract polaritonic characteristics and material parameters in a time scale that is at least 3 orders of magnitude faster than common fitting/processing procedures. The CNN-based analysis was validated by examining the experimental near-field images of charge-transfer plasmon polaritons at graphene/α-RuCl3 interfaces. Our work provides a general framework for extracting quantitative information from images generated with a variety of scanning probe methods.

97 MATHEMATICS AND COMPUTING↗

A phytophotonic approach to enhanced photosynthesis

Photosynthesis is the dominant biotic carbon sink on earth and hence presents an opportunity for enhanced sequestration of CO 2 . If the average net carbon fixation efficiency of terrestrial plants could be increased by 3.3%, all anthropogenic CO 2 accumulating in the atmosphere could instead be reduced and incorporated into terrestrial biomass. Plants make inefficient use of the overly abundant sunlight available to them, a result of having evolved to be competitive and survive highly dynamic environmental conditions rather than maximize photosynthetic productivity. We explore herein a phytophotonic approach to enhanced photosynthesis, whereby sunlight is redistributed by means of luminescent or persistent luminescent (PersL) materials. Phytophotonics has potential at varied scales, ranging from photobioreactors to greenhouses all the way to crops in the field, the latter having the potential to impact planetary CO 2 levels. The approach is three-fold: a spectral redistribution to relieve high-light-stress at the top surface of leaves and increasingly drive photosynthesis deeper in leaves and canopies; a minute-scale temporal redistribution to bridge periods of intermittent shade and reduce shock associated with variable light conditions; and a multiple-hour temporal redistribution to shift a fraction of high-intensity midday lighting to evening hours. Based on simulations of photoluminescent materials and light quality experiments with a model algal system, it is shown that while lengthening daylight hours will require significant improvements in PersL materials, the other two approaches show more immediate promise. We demonstrate a means of concentrating PersL light from SrAl 2 O 4 :Eu,Dy, approaching levels needed to effectively bridge periods of natural shade, and outline the scientific questions and technical hurdles remaining to realize the benefits of the proposed spectral shift.

59 BASIC BIOLOGICAL SCIENCES↗

An integrated manifold learning approach for high-dimensional data feature extractions and its applications to online process monitoring of additive manufacturing

As an effective dimension reduction and feature extraction technique, manifold learning has been successfully applied to high-dimensional data analysis. With the rapid development of sensor technology, a large amount of high-dimensional data such as image streams can be easily available. Thus, a promising application of manifold learning is in the field of sensor signal analysis, particular for the applications of online process monitoring and control using high-dimensional data. The objective of this study is to develop a manifold learning-based feature extraction method for process monitoring of Additive Manufacturing (AM) using online sensor data. Due to the non-parametric nature of most existing manifold learning methods, their performance in terms of computational efficiency, as well as noise resistance has yet to be improved. To address this issue, this study proposes an integrated manifold learning approach termed multi-kernel metric learning embedded isometric feature mapping (MKML-ISOMAP) for dimension reduction and feature extraction of online high-dimensional sensor data such as images. Based on the extracted features with the utilization of supervised classification and regression methods, an online process monitoring methodology for AM is implemented to identify the actual process quality status. Finally, in the numerical simulation and real-world case studies, the proposed method demonstrates excellent performance in both prediction accuracy and computational efficiency.

36 MATERIALS SCIENCE↗