Yaoyao Fiona Zhao

Lynn Cherif, Mutahar Safdar, Guy Lamouche et al.

Recent applications of machine learning in metal additive manufacturing (MAM) have demonstrated significant potential in addressing critical barriers to the widespread adoption of MAM technology. Recent research in this field emphasizes the importance of utilizing melt pool signatures for real-time defect prediction. While high-quality melt pool image data holds the promise of enabling precise predictions, there has been limited exploration into the utilization of cutting-edge spatiotemporal models that can harness the inherent transient and sequential characteristics of the additive manufacturing process. This research introduces and puts into practice some of the leading deep spatiotemporal learning models that can be adapted for the classification of melt pool image streams originating from various materials, systems, and applications. Specifically, it investigates two-stream networks comprising spatial and temporal streams, a recurrent spatial network, and a factorized 3D convolutional neural network. The capacity of these models to generalize when exposed to perturbations in melt pool image data is examined using data perturbation techniques grounded in real-world process scenarios. The implemented architectures demonstrate the ability to capture the spatiotemporal features of melt pool image sequences. However, among these models, only the Kinetics400 pre-trained SlowFast network, categorized as a two-stream network, exhibits robust generalization capabilities in the presence of data perturbations.

Jiarui Xie, Mutahar Safdar, Lequn Chen et al.

Various machine learning (ML)-based in-situ monitoring systems have been developed to detect anomalies and defects in laser additive manufacturing (LAM) processes. While multimodal fusion, which integrates data from visual, audio, and other modalities, can improve monitoring performance, it also increases hardware, computational, and operational costs. This paper introduces a cross-modality knowledge transfer (CMKT) methodology for LAM in-situ monitoring, which transfers knowledge from a source modality to a target modality. CMKT enhances the representativeness of the features extracted from the target modality, allowing the removal of source modality sensors during prediction. This paper proposes three CMKT methods: semantic alignment, fully supervised mapping, and semi-supervised mapping. The semantic alignment method establishes a shared encoded space between modalities to facilitate knowledge transfer. It employs a semantic alignment loss to align the distributions of identical groups (e.g., visual and audio defective groups) and a separation loss to distinguish different groups (e.g., visual defective and audio defect-free groups). The two mapping methods transfer knowledge by deriving features from one modality to another using fully supervised and semi-supervised learning approaches. In a case study for LAM in-situ defect detection, the proposed CMKT methods were compared with multimodal audio-visual fusion. The semantic alignment method achieved an accuracy of 98.6% while removing the audio modality during the prediction phase, which is comparable to the 98.2% accuracy obtained through multimodal fusion. Using explainable artificial intelligence, we discovered that semantic alignment CMKT can extract more representative features while reducing noise by leveraging the inherent correlations between modalities.

Jiarui Xie, Zhuo Yang, Chun-Chun Hu et al.

Powder bed fusion (PBF) is an emerging metal additive manufacturing (AM) technology that enables rapid fabrication of complex geometries. However, defects such as pores and balling may occur and lead to structural unconformities, thus compromising the mechanical performance of the part. This has become a critical challenge for quality assurance as the nature of some defects is stochastic during the process and invisible from the exterior. To address this issue, digital twin (DT) using machine learning (ML)-based modeling can be deployed for AM process monitoring and control. Melt pool is one of the most commonly observed physical phenomena for process monitoring, usually by high-speed cameras. Once labeled and preprocessed, the melt pool images are used to train ML-based models for DT applications such as process anomaly detection and print quality evaluation. Nonetheless, the reusability of DTs is restricted due to the wide variability of AM settings, including AM machines and monitoring instruments. The performance of the ML models trained using the dataset collected from one setting is usually compromised when applied to other settings. This paper proposes a knowledge transfer pipeline between different AM settings to enhance the reusability of AM DTs. The source and target datasets are collected from the National Institute of Standards and Technology and National Cheng Kung University with different cameras, materials, AM machines, and process parameters. The proposed pipeline consists of four steps: data preprocessing, data augmentation, domain alignment, and decision alignment. Compared with the model trained only using the source dataset, this pipeline increased the melt pool anomaly detection accuracy by 31% without any labeled training data from the target dataset.

Mutahar Safdar, Jiarui Xie, Hyunwoong Ko et al.

Data-driven research in Additive Manufacturing (AM) has gained significant success in recent years. This has led to a plethora of scientific literature to emerge. The knowledge in these works consists of AM and Artificial Intelligence (AI) contexts that have not been mined and formalized in an integrated way. Moreover, no tools or guidelines exist to support data-driven knowledge transfer from one context to another. As a result, data-driven solutions using specific AI techniques are being developed and validated only for specific AM process technologies. There is a potential to exploit the inherent similarities across various AM technologies and adapt the existing solutions from one process or problem to another using AI, such as Transfer Learning. We propose a three-step knowledge transferability analysis framework in AM to support data-driven AM knowledge transfer. As a prerequisite to transferability analysis, AM knowledge is featurized into identified knowledge components. The framework consists of pre-transfer, transfer, and post-transfer steps to accomplish knowledge transfer. A case study is conducted between flagship metal AM processes. Laser Powder Bed Fusion (LPBF) is the source of knowledge motivated by its relative matureness in applying AI over Directed Energy Deposition (DED), which drives the need for knowledge transfer as the less explored target process. We show successful transfer at different levels of the data-driven solution, including data representation, model architecture, and model parameters. The pipeline of AM knowledge transfer can be automated in the future to allow efficient cross-context or cross-process knowledge exchange.

Mutahar Safdar, Jiarui Xie, Andrei Mircea et al.

Data-driven research in Additive Manufacturing (AM) has gained significant success in recent years. This has led to a plethora of scientific literature to emerge. The knowledge in these works consists of AM and Artificial Intelligence (AI) contexts that have not been mined and formalized in an integrated way. It requires substantial effort and time to extract scientific information from these works. AM domain experts have contributed over two dozen review papers to summarize these works. However, information specific to AM and AI contexts still requires manual effort to extract. The recent success of foundation models such as BERT (Bidirectional Encoder Representations for Transformers) or GPT (Generative Pre-trained Transformers) on textual data has opened the possibility of expediting scientific information extraction. We propose a framework that enables collaboration between AM and AI experts to continuously extract scientific information from data-driven AM literature. A demonstration tool is implemented based on the proposed framework and a case study is conducted to extract information relevant to the datasets, modeling, sensing, and AM system categories. We show the ability of LLMs (Large Language Models) to expedite the extraction of relevant information from data-driven AM literature. In the future, the framework can be used to extract information from the broader design and manufacturing literature in the engineering discipline.

Manuel Sage, Martin Staniszewski, Yaoyao Fiona Zhao

Dispatching strategies for gas turbines (GTs) are changing in modern electricity grids. A growing incorporation of intermittent renewable energy requires GTs to operate more but shorter cycles and more frequently on partial loads. Deep reinforcement learning (DRL) has recently emerged as a tool that can cope with this development and dispatch GTs economically. The key advantages of DRL are a model-free optimization and the ability to handle uncertainties, such as those introduced by varying loads or renewable energy production. In this study, three popular DRL algorithms are implemented for an economic GT dispatch problem on a case study in Alberta, Canada. We highlight the benefits of DRL by incorporating an existing thermodynamic software provided by Siemens Energy into the environment model and by simulating uncertainty via varying electricity prices, loads, and ambient conditions. Among the tested algorithms and baseline methods, Deep Q-Networks (DQN) obtained the highest rewards while Proximal Policy Optimization (PPO) was the most sample efficient. We further propose and implement a method to assign GT operation and maintenance cost dynamically based on operating hours and cycles. Compared to existing methods, our approach better approximates the true cost of modern GT dispatch and hence leads to more realistic policies.

Manyi Li, Renshuai Tao, Yufan Liu et al.

With the rapid advancement of deep learning, particularly through generative adversarial networks (GANs) and diffusion models (DMs), AI-generated images, or ``deepfakes", have become nearly indistinguishable from real ones. These images are widely shared across Online Social Networks (OSNs), raising concerns about their misuse. Existing deepfake detection methods overlook the ``block effects" introduced by compression in OSNs, which obscure deepfake artifacts, and primarily focus on raw images, rarely encountered in real-world scenarios. To address these challenges, we propose PLADA (Pay Less Attention to Deceptive Artifacts), a novel framework designed to tackle the lack of paired data and the ineffective use of compressed images. PLADA consists of two core modules: Block Effect Eraser (B2E), which uses a dual-stage attention mechanism to handle block effects, and Open Data Aggregation (ODA), which processes both paired and unpaired data to improve detection. Extensive experiments across 26 datasets demonstrate that PLADA achieves a remarkable balance in deepfake detection, outperforming SoTA methods in detecting deepfakes on OSNs, even with limited paired data and compression. More importantly, this work introduces the ``block effect" as a critical factor in deepfake detection, providing a robust solution for open-world scenarios. Our code is available at https://github.com/ManyiLee/PLADA.

Xiao Yu, Yan Fang, Xiaojie Jin et al.

Audio-visual event parsing plays a crucial role in understanding multimodal video content, but existing methods typically rely on offline processing of entire videos with huge model sizes, limiting their real-time applicability. We introduce Online Audio-Visual Event Parsing (On-AVEP), a novel paradigm for parsing audio, visual, and audio-visual events by sequentially analyzing incoming video streams. The On-AVEP task necessitates models with two key capabilities: (1) Accurate online inference, to effectively distinguish events with unclear and limited context in online settings, and (2) Real-time efficiency, to balance high performance with computational constraints. To cultivate these, we propose the Predictive Future Modeling (PreFM) framework featured by (a) predictive multimodal future modeling to infer and integrate beneficial future audio-visual cues, thereby enhancing contextual understanding and (b) modality-agnostic robust representation along with focal temporal prioritization to improve precision and generalization. Extensive experiments on the UnAV-100 and LLP datasets show PreFM significantly outperforms state-of-the-art methods by a large margin with significantly fewer parameters, offering an insightful approach for real-time multimodal video understanding. Code is available at https://github.com/XiaoYu-1123/PreFM.

Manuel Sage, Joshua Campbell, Yaoyao Fiona Zhao

Energy arbitrage is one of the most profitable sources of income for battery operators, generating revenues by buying and selling electricity at different prices. Forecasting these revenues is challenging due to the inherent uncertainty of electricity prices. Deep reinforcement learning (DRL) emerged in recent years as a promising tool, able to cope with uncertainty by training on large quantities of historical data. However, without access to future electricity prices, DRL agents can only react to the currently observed price and not learn to plan battery dispatch. Therefore, in this study, we combine DRL with time-series forecasting methods from deep learning to enhance the performance on energy arbitrage. We conduct a case study using price data from Alberta, Canada that is characterized by irregular price spikes and highly non-stationary. This data is challenging to forecast even when state-of-the-art deep learning models consisting of convolutional layers, recurrent layers, and attention modules are deployed. Our results show that energy arbitrage with DRL-enabled battery control still significantly benefits from these imperfect predictions, but only if predictors for several horizons are combined. Grouping multiple predictions for the next 24-hour window, accumulated rewards increased by 60% for deep Q-networks (DQN) compared to the experiments without forecasts. We hypothesize that multiple predictors, despite their imperfections, convey useful information regarding the future development of electricity prices through a "majority vote" principle, enabling the DRL agent to learn more profitable control policies.

Manuel Sage, Martin Staniszewski, Yaoyao Fiona Zhao

The application of deep reinforcement learning algorithms to economic battery dispatch problems has significantly increased recently. However, optimizing battery dispatch over long horizons can be challenging due to delayed rewards. In our experiments we observe poor performance of popular actor-critic algorithms when trained on yearly episodes with hourly resolution. To address this, we propose an approach extending soft actor-critic (SAC) with learning from demonstrations. The special feature of our approach is that, due to the absence of expert demonstrations, the demonstration data is generated through simple, rule-based policies. We conduct a case study on a grid-connected microgrid and use if-then-else statements based on the wholesale price of electricity to collect demonstrations. These are stored in a separate replay buffer and sampled with linearly decaying probability along with the agent's own experiences. Despite these minimal modifications and the imperfections in the demonstration data, the results show a drastic performance improvement regarding both sample efficiency and final rewards. We further show that the proposed method reliably outperforms the demonstrator and is robust to the choice of rule, as long as the rule is sufficient to guide early training into the right direction.

Yikai Zhao, Jiekai Ma

Modern time series forecasting increasingly relies on complex ensemble models generated by AutoML systems like AutoGluon, delivering superior accuracy but with significant costs to transparency and interpretability. This paper introduces a comprehensive, dual-approach framework that addresses both the explainability and forecastability challenges in complex time series ensembles. First, we develop a surrogate-based explanation methodology that bridges the accuracy-interpretability gap by training a LightGBM model to faithfully mimic AutoGluon's time series forecasts, enabling stable SHAP-based feature attributions. We rigorously validated this approach through feature injection experiments, demonstrating remarkably high faithfulness between extracted SHAP values and known ground truth effects. Second, we integrated spectral predictability analysis to quantify each series' inherent forecastability. By comparing each time series' spectral predictability to its pure noise benchmarks, we established an objective mechanism to gauge confidence in forecasts and their explanations. Our empirical evaluation on the M5 dataset found that higher spectral predictability strongly correlates not only with improved forecast accuracy but also with higher fidelity between the surrogate and the original forecasting model. These forecastability metrics serve as effective filtering mechanisms and confidence scores, enabling users to calibrate their trust in both the forecasts and their explanations. We further demonstrated that per-item normalization is essential for generating meaningful SHAP explanations across heterogeneous time series with varying scales. The resulting framework delivers interpretable, instance-level explanations for state-of-the-art ensemble forecasts, while equipping users with forecastability metrics that serve as reliability indicators for both predictions and their explanations.

Yao Zhao, Haoyue Sun, Yantian Ding et al.

Reconstructing individual patient data (IPD) from Kaplan-Meier (KM) plots provides valuable insights for evidence synthesis in clinical research. However, existing approaches often rely on manual digitization, which is error-prone and lacks scalability. To address these limitations, we develop KM-GPT, the first fully automated, AI-powered pipeline for reconstructing IPD directly from KM plots with high accuracy, robustness, and reproducibility. KM-GPT integrates advanced image preprocessing, multi-modal reasoning powered by GPT-5, and iterative reconstruction algorithms to generate high-quality IPD without manual input or intervention. Its hybrid reasoning architecture automates the conversion of unstructured information into structured data flows and validates data extraction from complex KM plots. To improve accessibility, KM-GPT is equipped with a user-friendly web interface and an integrated AI assistant, enabling researchers to reconstruct IPD without requiring programming expertise. KM-GPT was rigorously evaluated on synthetic and real-world datasets, consistently demonstrating superior accuracy. To illustrate its utility, we applied KM-GPT to a meta-analysis of gastric cancer immunotherapy trials, reconstructing IPD to facilitate evidence synthesis and biomarker-based subgroup analyses. By automating traditionally manual processes and providing a scalable, web-based solution, KM-GPT transforms clinical research by leveraging reconstructed IPD to enable more informed downstream analyses, supporting evidence-based decision-making.

Mutahar Safdar, Gentry Wood, Max Zimmermann et al.

Rapid and reliable qualification of advanced materials remains a bottleneck in industrial manufacturing, particularly for heterogeneous structures produced via non-conventional additive manufacturing processes. This study introduces a novel framework that links microstructure informatics with a range of expert characterization knowledge using customized and hybrid vision-language representations (VLRs). By integrating deep semantic segmentation with pre-trained multi-modal models (CLIP and FLAVA), we encode both visual microstructural data and textual expert assessments into shared representations. To overcome limitations in general-purpose embeddings, we develop a customized similarity-based representation that incorporates both positive and negative references from expert-annotated images and their associated textual descriptions. This allows zero-shot classification of previously unseen microstructures through a net similarity scoring approach. Validation on an additively manufactured metal matrix composite dataset demonstrates the framework's ability to distinguish between acceptable and defective samples across a range of characterization criteria. Comparative analysis reveals that FLAVA model offers higher visual sensitivity, while the CLIP model provides consistent alignment with the textual criteria. Z-score normalization adjusts raw unimodal and cross-modal similarity scores based on their local dataset-driven distributions, enabling more effective alignment and classification in the hybrid vision-language framework. The proposed method enhances traceability and interpretability in qualification pipelines by enabling human-in-the-loop decision-making without task-specific model retraining. By advancing semantic interoperability between raw data and expert knowledge, this work contributes toward scalable and domain-adaptable qualification strategies in engineering informatics.

Zhiqiang Yang, Renshuai Tao, Xiaolong Zheng et al.

Existing deepfake detection methods heavily depend on labeled training data. However, as AI-generated content becomes increasingly realistic, even \textbf{human annotators struggle to distinguish} between deepfakes and authentic images. This makes the labeling process both time-consuming and less reliable. Specifically, there is a growing demand for approaches that can effectively utilize large-scale unlabeled data from online social networks. Unlike typical unsupervised learning tasks, where categories are distinct, AI-generated faces closely mimic real image distributions and share strong similarities, causing performance drop in conventional strategies. In this paper, we introduce the Dual-Path Guidance Network (DPGNet), to tackle two key challenges: (1) bridging the domain gap between faces from different generation models, and (2) utilizing unlabeled image samples. The method features two core modules: text-guided cross-domain alignment, which uses learnable prompts to unify visual and textual embeddings into a domain-invariant feature space, and curriculum-driven pseudo label generation, which dynamically exploit more informative unlabeled samples. To prevent catastrophic forgetting, we also facilitate bridging between domains via cross-domain knowledge distillation. Extensive experiments on \textbf{11 popular datasets}, show that DPGNet outperforms SoTA approaches by \textbf{6.3\%}, highlighting its effectiveness in leveraging unlabeled data to address the annotation challenges posed by the increasing realism of deepfakes.

Bogdan Bogachov, Yaoyao Fiona Zhao

Despite recent advancements in domain adaptation techniques for large language models, these methods remain computationally intensive, and the resulting models can still exhibit hallucination issues. Most existing adaptation methods do not prioritize reducing the computational resources required for fine-tuning and inference of language models. Hallucination issues have gradually decreased with each new model release. However, they remain prevalent in engineering contexts, where generating well-structured text with minimal errors and inconsistencies is critical. This work introduces a novel approach called the Small Language Graph (SLG), which is a lightweight adaptation solution designed to address the two key challenges outlined above. The system is structured in the form of a graph, where each node represents a lightweight expert - a small language model fine-tuned on specific and concise texts. The results of this study have shown that SLG was able to surpass conventional fine-tuning methods on the Exact Match metric by 3 times. Additionally, the fine-tuning process was 1.7 times faster compared to that of a larger stand-alone language model. These findings introduce a potential for small to medium-sized engineering companies to confidently use generative AI technologies, such as LLMs, without the necessity to invest in expensive computational resources. Also, the graph architecture and the small size of expert nodes offer a possible opportunity for distributed AI systems, thus potentially diverting the global need for expensive centralized compute clusters.

Jiarui Xie, Yaoyao Fiona Zhao

The deployment of machine learning (ML)-based process monitoring systems has significantly advanced additive manufacturing (AM) by enabling real-time defect detection, quality assessment, and process optimization. However, redundancy is a critical yet often overlooked challenge in the deployment and operation of ML-based AM process monitoring systems. Excessive redundancy leads to increased equipment costs, compromised model performance, and high computational requirements, posing barriers to industrial adoption. However, existing research lacks a unified definition of redundancy and a systematic framework for its evaluation and mitigation. This paper defines redundancy in ML-based AM process monitoring and categorizes it into sample-level, feature-level, and model-level redundancy. A comprehensive multi-level redundancy mitigation (MLRM) framework is proposed, incorporating advanced methods such as data registration, downscaling, cross-modality knowledge transfer, and model pruning to systematically reduce redundancy while improving model performance. The framework is validated through an ML-based in-situ defect detection case study for directed energy deposition (DED), demonstrating a 91% reduction in latency, a 47% decrease in error rate, and a 99.4% reduction in storage requirements. Additionally, the proposed approach lowers sensor costs and energy consumption, enabling a lightweight, cost-effective, and scalable monitoring system. By defining redundancy and introducing a structured mitigation framework, this study establishes redundancy analysis and mitigation as a key enabler of efficient ML-based process monitoring in production environments.