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DOE OSTI2026

Gearbox bearing crack growth prognostics and uncertainty quantification with physics-informed machine learning

This paper introduces the extreme theory of functional connections (X-TFC), a physics-informed machine learning algorithm, and tailors it to estimate the remaining useful life (RUL) of wind turbine gearbox bearings experiencing fatigue crack growth. Unlike purely data-driven methods, X-TFC embeds a physics model, based on Head's theory in this work, into its training objective. The core of X-TFC is a random-projection single-layer neural network trained via an extreme learning machine, which requires only limited damage progression data and solves for output weights with a least-squares optimization algorithm. A composite loss function balances the network's fit to observed degradation data against the residuals of the governing crack growth differential equation, ensuring the learned damage trajectory remains physically plausible. When applied to a vibration-based health-index (HI) dataset measured during the growth of a crack on the inner ring of a high-speed bearing in a wind turbine gearbox (Bechhoefer and Dubé, 2020), X-TFC achieves near-zero prediction bias. Even when trained on only the first 10 %–20 % of the damage progression data, with sufficient physics weighting its predictions remain monotonic and smooth, delivering high prognosability and trendability. To quantify the epistemic uncertainty, we employ a Monte Carlo ensemble of independently initialized X-TFC models trained on noise-perturbed data, which yields confidence intervals around each RUL estimate and captures both model-parameter and epistemic uncertainty. In addition to a vibration-based HI, we demonstrate that the proposed framework can be directly applied to a supervisory control and data acquisition (SCADA) data-based HI (Eftekhari Milani et al., 2026) measured during similar wind turbine gearbox bearing crack faults, preserving its accuracy and interpretability. This extension shows the versatility of our approach, which is applicable to bearings of multiple gearbox manufacturers, models, and ratings using only SCADA data. By integrating domain knowledge with machine learning, X-TFC offers a rapid, reliable tool for crack prognostics. Its adaptability to other bearing failure modes, such as pitch bearing ring cracks, positions X-TFC as a powerful enabler of data-driven, physics-informed asset management in the wind energy sector and beyond.

17 WIND ENERGY↗

DOE OSTI2016

Estimating heterotrophic respiration at large scales: challenges, approaches, and next steps

Heterotrophic respiration (HR), the aerobic and anaerobic processes mineralizing organic matter, is a key carbon flux but one impossible to measure at scales significantly larger than small experimental plots. This impedes our ability to understand carbon and nutrient cycles, benchmark models, or reliably upscale point measurements. Given that a new generation of highly mechanistic, genomic-specific global models is not imminent, we suggest that a useful step to improve this situation would be the development of "Decomposition Functional Types" (DFTs). Analogous to plant functional types (PFTs), DFTs would abstract and capture important differences in HR metabolism and flux dynamics, allowing models to efficiently group and vary these characteristics across space and time. We argue that DFTs should be initially informed by top-down expert opinion, but ultimately developed using bottom-up, data-driven analyses, and provide specific examples of potential dependent and independent variables that could be used. We present and discuss an example clustering analysis to show how model-produced annual HR can be broken into distinct groups associated with global variability in biotic and abiotic factors, and demonstrate that these groups are distinct from already-existing PFTs. A similar analysis, incorporating observational data, could form a basis for future DFTs. Finally, we suggest next steps and critical priorities: collection and synthesis of existing data; more in-depth analyses combining open data with high-performance computing; rigorous testing of analytical results; and planning by the global modeling community for decoupling decomposition from fixed site data. These are all critical steps to build a foundation for DFTs in global models, thus providing the ecological and climate change communities with robust, scalable estimates of HR at large scales.

carbon cycle↗

DOE OSTI2021

A Taxonomic Classification Approach for Global Spatio-temporal Data

The World Bank, World Health Organization, and other major vendors collectively provide thousands of global time series datasets that focus on issues of the environment, public health, economics, violence, education, and national security. Sorting these data into meaningful information requires the use of data mining techniques to cluster trends into an orderly and manageable number of cases. The World SpatioTemporal Analytics and Mapping (WSTAMP) project database (wstamp.ornl.gov) was developed to spatiotemporally harmonize global vendor data (23,300+ attributes, 200+ locations, 50+ years). Within the WSTAMP analytical environment, Dynamic Time Warping (DTW) has been a highly effective data-driven approach for clustering and mapping these time series into national spatiotemporal behavior maps. Two significant properties have surfaced from this work. First, several recognizable cluster patterns have emerged and persist across a range of locations, attributes, and time frames (e.g., increasing, decreasing, rebounding, peak, oscillating). Secondly, practitioners engaging WSTAMP have noted the explanatory and anticipatory value of these patterns and articulated particular interest in detecting them within the spatiotemporal cube. This need was addressed by shifting DTW-based clustering from an open ended, data-driven implementation to a taxonomic pattern matching approach. This paper presents the method including implementation strategies for visualization and human computer interaction and applies the approach to a sample data set and concludes with next steps.

Stewart, Robert↗

DOE OSTI2023

Advanced data analysis in inertial confinement fusion and high energy density physics

Bayesian analysis enables flexible and rigorous definition of statistical model assumptions with well-characterized propagation of uncertainties and resulting inferences for single-shot, repeated, or even cross-platform data. This approach has a strong history of application to a variety of problems in physical sciences ranging from inference of particle mass from multi-source high-energy particle data to analysis of black-hole characteristics from gravitational wave observations. The recent adoption of Bayesian statistics for analysis and design of high-energy density physics (HEDP) and inertial confinement fusion (ICF) experiments has provided invaluable gains in expert understanding and experiment performance. In this Review, we discuss the basic theory and practical application of the Bayesian statistics framework. We highlight a variety of studies from the HEDP and ICF literature, demonstrating the power of this technique. Due to the computational complexity of multi-physics models needed to analyze HEDP and ICF experiments, Bayesian inference is often not computationally tractable. Two sections are devoted to a review of statistical approximations, efficient inference algorithms, and data-driven methods, such as deep-learning and dimensionality reduction, which play a significant role in enabling use of the Bayesian framework. We provide additional discussion of various applications of Bayesian and machine learning methods that appear to be sparse in the HEDP and ICF literature constituting possible next steps for the community. We conclude by highlighting community needs, the resolution of which will improve trust in data-driven methods that have proven critical for accelerating the design and discovery cycle in many application areas.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

Utility of a hybrid approach to the hadronic vacuum polarization contribution to the muon anomalous magnetic moment

An accurate calculation of the leading-order hadronic vacuum polarization (LOHVP) contribution to the anomalous magnetic moment of the muon ( a μ ) is key to determining whether a discrepancy, suggesting new physics, exists between the Standard Model and experimental results. This calculation can be expressed as an integral over Euclidean time of a current-current correlator G ( t ) , where G ( t ) can be calculated using lattice QCD or, with dispersion relations, from experimental data for e + e − → hadrons . The BMW/DMZ collaboration recently presented a hybrid approach in which G ( t ) is calculated using lattice QCD for most of the contributing t range, but using experimental data for the largest t (lowest energy) region. Here we study the advantages of varying the position t = t 1 separating lattice QCD from data-driven contributions. The total LOHVP contribution should be independent of t 1 , providing both a test of the experimental input and the robustness of the hybrid approach. We use this criterion and a correlated fit to show that Fermilab/HPQCD/MILC lattice QCD results from 2019 strongly favor the CMD-3 cross section data for e + e − → π + π − over a combination of earlier experimental results for this channel. Further, the resulting total LOHVP contribution obtained is consistent with the result obtained by BMW/DMZ, and supports the scenario in which there is no significant discrepancy between the experimental value for a μ and that expected in the Standard Model. We then discuss how improved lattice results in this hybrid approach could provide a more accurate total LOHVP across a wider range of t 1 values with an uncertainty that is smaller than that from either lattice QCD or data-driven approaches on their own. Published by the American Physical Society 2025

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2018

Engineering Design with Digital Thread

Digital Thread is a data-driven architecture that links together information generated from across the product lifecycle. Though Digital Thread is gaining traction as a digital communication framework to streamline design, manufacturing, and operation processes in order to more efficiently design, build, and maintain engineering products, a principled mathematical formulation describing the manner in which Digital Thread can be used for critical design decisions remains absent. The contribution of this paper is to present such a formulation from the context of a data-driven design and decision problem under uncertainty. This formulation accounts for the fact that the design process is highly iterative and not all information is available at once. Output design decisions are made not only on what data to collect but also on the costs and benefits involved in experimentation and sensor instrumentation to collect that data. The mathematical formulation is illustrated through an example design of a structural fiber-steered composite component. In this example, the methodology highlights how different sequencing of small-scale experimentation with manufacturing and deployment lead to different designs and different associated costs.

42 ENGINEERING↗

DOE OSTI2023

Machine learning from RANS and LES to inform coarse grid simulations

Nuclear system thermal hydraulic analysis has historically relied on computationally inexpensive 1D codes. However, such tools are unable to capture multiscale multidimensional effects in large nuclear reactor enclosures. On the other hand, simulations with higher fidelity can be too expensive for such purposes. One of the ways to reduce computational cost is to perform simulations on a coarse grid, which, unfortunately, introduces large discretization errors. In this paper, two high-to-low data-driven approaches are investigated: (1) a coarse grid turbulence model to predict eddy viscosity and (2) correction of errors in coarse grid velocity fields. The approaches aim to reduce grid- and turbulence model-induced errors in coarse grid Reynolds-averaged Navier–Stokes (RANS) simulations. Two sources of high-fidelity data, RANS and large eddy simulations (LES), are explored. To extract the eddy viscosity from the LES data, an inverse optimization problem is solved. However, the LES eddy viscosity is shown to be comparable to the RANS eddy viscosity in terms of error reduction. Therefore, the directly available RANS eddy viscosity was used to develop a coarse grid data-driven turbulence model. Additionally, error correction in velocity is used to reduce the remaining uncertainties and bring the results closer to reality. In conclusion, the performance of the frameworks is demonstrated for a scaled upper plenum of a gas-cooled reactor facility.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Permutationally Invariant Networks for Enhanced Sampling (PINES): Discovery of Multimolecular and Solvent-Inclusive Collective Variables

The typically rugged nature of molecular free energy landscapes can frustrate eﬃcient sampling of the thermodynamically relevant phase space due to the presence of high free energy barriers. Enhanced sampling techniques can improve phase space exploration by accelerating sampling along particular collective variables (CVs). A number of techniques exist for data-driven discovery of CVs parameterizing the important large scale motions of the system. A challenge to CV discovery is learning CVs invariant to symmetries of the molecular system, frequently rigid translation, rigid rotation, and permutational relabeling of identical particles. Of these, permutational invariance has proved a persistent challenge in frustrating the data-driven discovery of multi-molecular CVs in systems of self-assembling particles and solvent-inclusive CVs for solvated systems. In this work, we integrate Permutation Invariant Vector (PIV) featurizations with autoencoding neural networks to learn nonlinear CVs invariant to translation, rotation, and permutation, and perform interleaved rounds of CV discovery and enhanced sampling to iteratively expand sampling of configurational phase space and obtain converged CVs and free energy landscapes. Here, we demonstrate the Permutationally Invariant Network for Enhanced Sampling (PINES) approach in applications to the self-assembly of a 13-atom Argon cluster, association/dissociation of a NaCl ion pair in water, and hydrophobic collapse of a C 45 H 92 n-pentatetracontane polymer chain. We make the approach freely available as a new module within the PLUMED2 enhanced sampling libraries.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

A machine learning approach for determining temperature-dependent bandgap of metal oxides utilizing Allen–Heine–Cardona theory and O’Donnell model parameterization

To evaluate the high temperature sensing properties of metal oxide and perovskite materials suitable for use in combustion environments, it is necessary to understand the temperature dependence of their bandgaps. Although such temperature-driven changes can be calculated via the Allen–Heine–Cardona (AHC) theory, which assesses electron–phonon coupling for the bandgap correction at given temperatures, this approach is computationally demanding. Another approach to predict bandgap temperature-dependence is the O’Donnell model, which uses analytical expressions with multiple fitting parameters that require bandgap information at 0 K. This work employs data-driven Gaussian process regression (GPR) to predict the parameters employed in the O’Donnell model from a set of physical features. We use a sample of 54 metal oxides for which density functional theory has been performed to calculate the bandgap at 0 K, and the AHC calculations have been carried out to determine the shift in the bandgap at non-zero temperatures. As the AHC calculations are impractical for high-throughput screening of materials, the developed GPR model attempts to alleviate this issue by predicting the O'Donnell parameters purely from physical features. To mitigate the reliability issues arising from the very small size of the dataset, we apply a Bayesian technique to improve the generalizability of the data-driven models as well as quantify the uncertainty associated with the predictions. The method captures well the overall trend of the O’Donnell parameters with respect to a reduced feature set obtained by transforming the available physical features. Quantifying the associated uncertainty helps us understand the reliability of the predictions of the O’Donnell parameters and, therefore, the bandgap as a function of temperature for any novel material.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Validation and parameterization of a novel physics-constrained neural dynamics model applied to turbulent fluid flow

We report, in fluid physics, data-driven models to enhance or accelerate time to solution are becoming increasingly popular for many application domains, such as alternatives to turbulence closures, system surrogates, or for new physics discovery. In the context of reduced order models of high-dimensional time-dependent fluid systems, machine learning methods grant the benefit of automated learning from data, but the burden of a model lies on its reduced-order representation of both the fluid state and physical dynamics. In this work, we build a physics-constrained, data-driven reduced order model for Navier–Stokes equations to approximate spatiotemporal fluid dynamics in the canonical case of isotropic turbulence in a triply periodic box. The model design choices mimic numerical and physical constraints by, for example, implicitly enforcing the incompressibility constraint and utilizing continuous neural ordinary differential equations for tracking the evolution of the governing differential equation. We demonstrate this technique on a three-dimensional, moderate Reynolds number turbulent fluid flow. In assessing the statistical quality and characteristics of the machine-learned model through rigorous diagnostic tests, we find that our model is capable of reconstructing the dynamics of the flow over large integral timescales, favoring accuracy at the larger length scales. More significantly, comprehensive diagnostics suggest that physically interpretable model parameters, corresponding to the representations of the fluid state and dynamics, have attributable and quantifiable impact on the quality of the model predictions and computational complexity.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

Editorial: Hydrology, ecology, and nutrient biogeochemistry at the terrestrial-aquatic interface

Terrestrial-aquatic interfaces (TAI) play important roles in mediating the exchange of water and chemicals between land, surface and subsurface water systems, which is tightly coupled with biogeochemical transformations that influence water quality and ecosystem health (Harvey and Gooseff, 2015; Harvey et al., 2019). Understanding and predicting the interactions between the hydrologic, ecologic, and biogeochemical processes at those interfaces is crucial for the sustainable management of water resources and promotion of healthy ecosystems under different environmental stresses and disturbances, including climate change, human activities, and more frequent occurrence of extreme events. Both process-based and data-driven approaches have emerged to address critical challenges at TAIs as integral parts of the Earth system (e.g., Ward and Packman, 2019; Chen et al., 2021; Dwivedi et al., 2022). In this Research Topic, we sought research that advances the understanding of coupled hydrologic, ecologic, and biogeochemical processes along various TAIs from the summit to sea, e.g., river corridors and coastal TAI systems. We invited observational, experimental, theoretical, analytical, numerical, and data-driven research that aims to understand hydro-biogeochemical processes such as the redox dynamics and biogeochemical transformations of carbon, nutrients, and metals occurring at the TAIs and address their heterogeneity and scaling challenges.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Machine learning neutrino-nucleus cross sections

Neutrino-nucleus scattering cross sections are critical theoretical inputs for long-baseline neutrino oscillation experiments. However, robust modeling of these cross sections remains challenging. For a simple but physically motivated toy model of the DUNE experiment, we demonstrate that an accurate neural-network model of the cross section—leveraging only Standard-Model symmetries—can be learned from near-detector data. We perform a neutrino oscillation analysis with simulated far-detector events, finding that oscillation analysis results enabled by our data-driven cross-section model approach the theoretical limit achievable with perfect prior knowledge of the cross section. We further quantify the effects of flux shape and detector resolution uncertainties as well as systematics from cross-section mismodeling. This proof-of-principle study highlights the potential of future neutrino near-detector datasets and data-driven cross-section models.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2026

Machine Learning Neutrino-Nucleus Cross Sections

Neutrino-nucleus scattering cross sections are critical theoretical inputs for long-baseline neutrino oscillation experiments. However, robust modeling of these cross sections remains challenging. For a simple but physically motivated toy model of the DUNE experiment, we demonstrate that an accurate neural-network model of the cross section—leveraging only Standard-Model symmetries— can be learned from near-detector data. We perform a neutrino oscillation analysis with simulated far-detector events, finding that oscillation analysis results enabled by our data-driven cross-section model approach the theoretical limit achievable with perfect prior knowledge of the cross section. We further quantify the effects of flux shape and detector resolution uncertainties as well as systematics from cross-section mismodeling. This proof-of-principle study highlights the potential of future neutrino near-detector datasets and data-driven cross-section models.

Tame-Narvaez, Karla [Fermilab] (ORCID:000000022249↗

DOE OSTI2018

Integrating diagnostics and model-based optimization

Energy Management and Information Systems are a family of analytics technologies that include energy information systems, fault detection and diagnostics (FDD), and automated system optimization tools. Such systems have the potential to enable buildings to meet energy management goals of reducing total energy consumption and cost. Most current market offerings use data-driven and rule-based analytics. However, the use of physics-based models in the analytics offers potential improvements by providing an accurate estimation of outputs based on representation of the physical principles governing the building system behaviors. This also permits the use of design stage models to inform commissioning and operation. This paper describes the development and testing of a hybrid data-driven and physics model-based operational tool for energy efficiency in central cooling plants. The tool offers FDD functionality, setpoint optimization, and visualization of key performance parameters. It was demonstrated at a university campus in the mixed-humid ASHRAE Climate Zone 4A. Key performance metrics that were analyzed include plant electricity use reduction, plant model calibration, and system economics. Annual simulations indicate the tool can provide electricity savings of greater than 10% for approximately six months of the year, mainly during the winter season when wet bulb temperatures are low, though only 1.38% savings for the entire year. Additionally, over a 4-day period in April, recommended optimal setpoints were implemented, resulting in 17% savings versus metered baseline consumption. With respect to model calibration, the difference between model-predicted and measured parameters was less than 10% for 90% of data points acquired for three of six chillers, and for each ten cooling towers. Finally, the tool users reported that satisfaction with the capabilities was equal to or better than that with the preexisting BAS system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2018

An operational definition of quark and gluon jets

While “quark” and “gluon” jets are often treated as separate, well-defined objects in both theoretical and experimental contexts, no precise, practical, and hadron-level definition of jet flavor presently exists. To remedy this issue, we develop and advocate for a data-driven, operational definition of quark and gluon jets that is readily applicable at colliders. Rather than specifying a per-jet flavor label, we aggregately define quark and gluon jets at the distribution level in terms of measured hadronic cross sections. Intuitively, quark and gluon jets emerge as the two maximally separable categories within two jet samples in data. Benefiting from recent work on data-driven classifiers and topic modeling for jets, we show that the practical tools needed to implement our definition already exist for experimental applications. As an informative example, we demonstrate the power of our operational definition using Z+jet and dijet samples, illustrating that pure quark and gluon distributions and fractions can be successfully extracted in a fully well-defined manner.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2024

Towards accurate prediction of configurational disorder properties in materials using graph neural networks

Abstract The prediction of configurational disorder properties, such as configurational entropy and order-disorder phase transition temperature, of compound materials relies on efficient and accurate evaluations of configurational energies. Previous cluster expansion methods are not applicable to configurationally-complex material systems, including those with atomic distortions and long-range orders. In this work, we propose to leverage the versatile expressive capabilities of graph neural networks (GNNs) for efficient evaluations of configurational energies and present a workflow combining attention-based GNNs and Monte Carlo simulations to calculate the disorder properties. Using the dataset of face-centered tetragonal gold copper without and with local atomic distortions as an example, we demonstrate that the proposed data-driven framework enables the prediction of phase transition temperatures close to experimental values. We also elucidate that the variance of the energy deviations among configurations controls the prediction accuracy of disorder properties and can be used as the target loss function when training and selecting the GNN models. The work serves as a fundamental step toward a data-driven paradigm for the accelerated design of configurationally-complex functional material systems.

Chemistry↗

DOE OSTI2024

Progressive transfer learning for advancing machine learning-based reduced-order modeling

Abstract To maximize knowledge transfer and improve the data requirement for data-driven machine learning (ML) modeling, a progressive transfer learning for reduced-order modeling (p-ROM) framework is proposed. A key concept of p-ROM is to selectively transfer knowledge from previously trained ML models and effectively develop a new ML model(s) for unseen tasks by optimizing information gates in hidden layers. The p-ROM framework is designed to work with any type of data-driven ROMs. For demonstration purposes, we evaluate the p-ROM with specific Barlow Twins ROMs (p-BT-ROMs) to highlight how progress learning can apply to multiple topological and physical problems with an emphasis on a small training set regime. The proposed p-BT-ROM framework has been tested using multiple examples, including transport, flow, and solid mechanics, to illustrate the importance of progressive knowledge transfer and its impact on model accuracy with reduced training samples. In both similar and different topologies, p-BT-ROM achieves improved model accuracy with much less training data. For instance, p-BT-ROM with four-parent (i.e., pre-trained models) outperforms the no-parent counterpart trained on data nine times larger. The p-ROM framework is poised to significantly enhance the capabilities of ML-based ROM approaches for scientific and engineering applications by mitigating data scarcity through progressively transferring knowledge.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Deep learning interfacial momentum closures in coarse-mesh CFD two-phase flow simulation using validation data

Multiphase flow phenomena have been widely observed in the industrial applications while it remains a challenging yet unsolved problems. Three-dimensional computational fluid dynamics (CFD) approaches resolve the flow fields on a finer special and temporal scales which can complement the dedicated experimental study. However, closures have to be introduced to reflect the underlying physics in multiphase flow. Among them, the interfacial forces, including drag, lift, turbulent dispersion and wall lubrication forces, play in important role on the bubble’s distribution and migration in liquid-vapor two-phase flow. Development of those closures traditionally rely on the experimental data and analytical derivation with simplified assumptions which usually cannot deliver a universal solution across wide range of flow conditions. In this paper, a data-driven approach, named as Feature Similarity Measurement (FSM), is developed and applied to improve the simulation capability of two-phase flow with coarse-mesh CFD approach. Interfacial momentum transfer in adiabatic bubbly flow serves as the focus of the present study. Both a mature and a simplified set of interfacial closures are taken as the low fidelity data. Experimental data and fine mesh CFD simulations results are adopted as high-fidelity data. Qualitative and quantitative analysis are performed in this paper which reveals that FSM can substantially improve the prediction of coarse mesh CFD model regardless of the choice of interfacial closures and it provides scalability and consistency across discontinuous flow regimes. Furthermore, it demonstrates that data-driven method can aid the multiphase flow modeling by exploring the connections between local physical features and simulation errors.

97 MATHEMATICS AND COMPUTING↗