Wing Kam Liu

Owen Huang, Sourav Saha, Jiachen Guo et al.

Recent advances in operator learning theory have improved our knowledge about learning maps between infinite dimensional spaces. However, for large-scale engineering problems such as concurrent multiscale simulation for mechanical properties, the training cost for the current operator learning methods is very high. The article presents a thorough analysis on the mathematical underpinnings of the operator learning paradigm and proposes a kernel learning method that maps between function spaces. We first provide a survey of modern kernel and operator learning theory, as well as discuss recent results and open problems. From there, the article presents an algorithm to how we can analytically approximate the piecewise constant functions on R for operator learning. This implies the potential feasibility of success of neural operators on clustered functions. Finally, a k-means clustered domain on the basis of a mechanistic response is considered and the Lippmann-Schwinger equation for micro-mechanical homogenization is solved. The article briefly discusses the mathematics of previous kernel learning methods and some preliminary results with those methods. The proposed kernel operator learning method uses graph kernel networks to come up with a mechanistic reduced order method for multiscale homogenization.

Yangfan Li, Satyajit Mojumder, Ye Lu et al.

A digital twin (DT) is a virtual representation of physical process, products and/or systems that requires a high-fidelity computational model for continuous update through the integration of sensor data and user input. In the context of laser powder bed fusion (LPBF) additive manufacturing, a digital twin of the manufacturing process can offer predictions for the produced parts, diagnostics for manufacturing defects, as well as control capabilities. This paper introduces a parameterized physics-based digital twin (PPB-DT) for the statistical predictions of LPBF metal additive manufacturing process. We accomplish this by creating a high-fidelity computational model that accurately represents the melt pool phenomena and subsequently calibrating and validating it through controlled experiments. In PPB-DT, a mechanistic reduced-order method-driven stochastic calibration process is introduced, which enables the statistical predictions of the melt pool geometries and the identification of defects such as lack-of-fusion porosity and surface roughness, specifically for diagnostic applications. Leveraging data derived from this physics-based model and experiments, we have trained a machine learning-based digital twin (PPB-ML-DT) model for predicting, monitoring, and controlling melt pool geometries. These proposed digital twin models can be employed for predictions, control, optimization, and quality assurance within the LPBF process, ultimately expediting product development and certification in LPBF-based metal additive manufacturing.

Chanwook Park, Brian Kim, Jiachen Guo et al.

Neural networks and machine learning models for uncertainty quantification suffer from limited scalability and poor reliability compared to their deterministic counterparts. In industry-scale active learning settings, where generating a single high-fidelity simulation may require days or weeks of computation and produce data volumes on the order of gigabytes, they quickly become impractical. This paper proposes a scalable and reliable Bayesian surrogate model, termed the Bayesian Interpolating Neural Network (B-INN). The B-INN combines high-order interpolation theory with tensor decomposition and alternating direction algorithm to enable effective dimensionality reduction without compromising predictive accuracy. We theoretically show that the function space of a B-INN is a subset of that of Gaussian processes, while its Bayesian inference exhibits linear complexity, $\mathcal{O}(N)$, with respect to the number of training samples. Numerical experiments demonstrate that B-INNs can be from 20 times to 10,000 times faster with a robust uncertainty estimation compared to Bayesian neural networks and Gaussian processes. These capabilities make B-INN a practical foundation for uncertainty-driven active learning in large-scale industrial simulations, where computational efficiency and robust uncertainty calibration are paramount.

Chanwook Park, Sourav Saha, Jiachen Guo et al.

Artificial intelligence (AI) has revolutionized software development, shifting from task-specific codes (Software 1.0) to neural network-based approaches (Software 2.0). However, applying this transition in engineering software presents challenges, including low surrogate model accuracy, the curse of dimensionality in inverse design, and rising complexity in physical simulations. We introduce an interpolating neural network (INN), grounded in interpolation theory and tensor decomposition, to realize Engineering Software 2.0 by advancing data training, partial differential equation solving, and parameter calibration. INN offers orders of magnitude fewer trainable/solvable parameters for comparable model accuracy than traditional multi-layer perceptron (MLP) or physics-informed neural networks (PINN). Demonstrated in metal additive manufacturing, INN rapidly constructs an accurate surrogate model of Laser Powder Bed Fusion (L-PBF) heat transfer simulation, achieving sub-10-micrometer resolution for a 10 mm path in under 15 minutes on a single GPU. This makes a transformative step forward across all domains essential to engineering software.

Wei Liu, Satyajit Mojumder, Wing Kam Liu et al.

A representative volume element (RVE) is a reasonably small unit of microstructure that can be simulated to obtain the same effective properties as the entire microstructure sample. Finite element (FE) simulation of RVEs, as opposed to much larger samples, saves computational expense, especially in multiscale modeling. Therefore, it is desirable to have a framework that determines RVE size prior to FE simulations. Existing methods select the RVE size based on when the FE-simulated properties of samples of increasing size converge with insignificant statistical variations, with the drawback that many samples must be simulated. We propose a simulation-free alternative that determines RVE size based only on a micrograph. The approach utilizes a machine learning model trained to implicitly characterize the stochastic nature of the input micrograph. The underlying rationale is to view RVE size as the smallest moving window size for which the stochastic nature of the microstructure within the window is stationary as the window moves across a large micrograph. For this purpose, we adapt a recently developed Fisher score-based framework for microstructure nonstationarity monitoring. Because the resulting RVE size is based solely on the micrograph and does not involve any FE simulation of specific properties, it constitutes an RVE for any property of interest that solely depends on the microstructure characteristics. Through numerical experiments of simple and complex microstructures, we validate our approach and show that our selected RVE sizes are consistent with when the chosen FE-simulated properties converge.

Reza T. Batley, Chanwook Park, Wing Kam Liu et al.

Data-driven science and computation have advanced immensely to construct complex functional relationships using trainable parameters. However, efficiently discovering interpretable and accurate closed-form expressions from complex dataset remains a challenge. The article presents a novel approach called Explainable Hierarchical Deep Learning Neural Networks or Ex-HiDeNN that uses an accurate, frugal, fast, separable, and scalable neural architecture with symbolic regression to discover closed-form expressions from limited observation. The article presents the two-step Ex-HiDeNN algorithm with a separability checker embedded in it. The accuracy and efficiency of Ex-HiDeNN are tested on several benchmark problems, including discerning a dynamical system from data, and the outcomes are reported. Ex-HiDeNN generally shows outstanding approximation capability in these benchmarks, producing orders of magnitude smaller errors compared to reference data and traditional symbolic regression. Later, Ex-HiDeNN is applied to three engineering applications: a) discovering a closed-form fatigue equation, b) identification of hardness from micro-indentation test data, and c) discovering the expression for the yield surface with data. In every case, Ex-HiDeNN outperformed the reference methods used in the literature. The proposed method is built upon the foundation and published works of the authors on Hierarchical Deep Learning Neural Network (HiDeNN) and Convolutional HiDeNN. The article also provides a clear idea about the current limitations and future extensions of Ex-HiDeNN.

Lei Zhang, Ye Lu, Shaoqiang Tang et al.

This paper presents a proper generalized decomposition (PGD) based reduced-order model of hierarchical deep-learning neural networks (HiDeNN). The proposed HiDeNN-PGD method keeps both advantages of HiDeNN and PGD methods. The automatic mesh adaptivity makes the HiDeNN-PGD more accurate than the finite element method (FEM) and conventional PGD, using a fraction of the FEM degrees of freedom. The accuracy and convergence of the method have been studied theoretically and numerically, with a comparison to different methods, including FEM, PGD, HiDeNN and Deep Neural Networks. In addition, we theoretically showed that the PGD converges to FEM at increasing modes, and the PGD error is a direct sum of the FEM error and the mode reduction error. The proposed HiDeNN-PGD performs high accuracy with orders of magnitude fewer degrees of freedom, which shows a high potential to achieve fast computations with a high level of accuracy for large-size engineering problems.