Pioneering ML-driven framework for in-situ vertical surface roughness prediction in LPBF

A novel machine learning-based approach for in-situ surface roughness prediction in laser powder-bed fusion

This study focuses on using various machine learning (ML) models to evaluate the shear behaviors of ultra-high-performance concrete (UHPC) beams reinforced with glass fiber-reinforced polymer (GFRP) bars. The main objective of the study is to predict the shear strength of UHPC beams reinforced with GFRP bars using ML models. We use four different ML models: support vector machine (SVM), artificial neural network (ANN), random forest (R.F.), and extreme gradient boosting (XGBoost). The experimental database used in the study is acquired from various literature sources and comprises 54 test observations with 11 input features. These input features are likely parameters related to the composition, geometry, and properties of the UHPC beams and GFRP bars. To ensure the ML models' generalizability and scalability, random search methods are utilized to tune the hyperparameters of the algorithms. This tuning process helps improve the performance of the models when predicting the shear strength. The study uses the ACI318M-14 and Eurocode 2 standard building codes to predict the shear capacity behavior of GFRP bars-reinforced UHPC I-shaped beams. The ML models' predictions are compared to the results obtained from these building code standards. According to the findings, the XGBoost model demonstrates the highest predictive test performance among the investigated ML models. The study employs the SHAP (SHapley Additive exPlanations) analysis to assess the significance of each input parameter in the ML models' predictive capabilities. A Taylor diagram is used to statistically compare the accuracy of the ML models. This study concludes that ML models, particularly XGBoost, can effectively predict the shear capacity behavior of GFRP bars-reinforced UHPC I-shaped beams.

Predicting defects in laser powder bed fusion using in-situ thermal imaging data and machine learning

Summary A meticulous interpretation of steady-state or unsteady-state relative permeability (Kr) experimental data is required to determine a complete set of Kr curves. In this work, different machine learning (ML) models were developed to assist in a faster estimation of these curves from steady-state drainage coreflooding experimental runs. These ML algorithms include gradient boosting (GB), random forest (RF), extreme gradient boosting (XGB), and deep neural network (DNN) with a main focus on and comparison of the two latter algorithms (XGB and DNN). Based on existing mathematical models, a leading-edge framework was developed where a large database of Kr and capillary pressure (Pc) curves were generated. This database was used to perform thousands of coreflood simulation runs representing oil-water drainage steady-state experiments. The results obtained from these simulation runs, mainly pressure drop along with other conventional core analysis data, were used to estimate analytical Kr curves based on Darcy’s law. These analytically estimated Kr curves along with the previously generated Pc curves were fed as features into the ML model. The entire data set was split into 80% for training and 20% for testing. The k-fold cross-validation technique was applied to increase the model’s accuracy by splitting 80% of the training data into 10 folds. In this manner, for each of the 10 experiments, nine folds were used for training and the remaining fold was used for model validation. Once the model was trained and validated, it was subjected to blind testing on the remaining 20% of the data set. The ML model learns to capture fluid flow behavior inside the core from the training data set. In terms of applicability of these ML models, two sets of experimental data were needed as input; the first was the analytically estimated Kr curves from the steady-state drainage coreflooding experiments, while the other was the Pc curves estimated from centrifuge or mercury injection capillary pressure (MICP) measurements. The trained/tested model was then able to estimate Kr curves based on the experimental results fed as input. Furthermore, to test the performance of the ML model when only one set of experimental data is available to an end user, a recurrent neural network (RNN) algorithm was trained/tested to predict Kr curves in the absence of Pc curves as an input. The performance of the three developed models (XGB, DNN, and RNN) was assessed using the values of the coefficient of determination (R2) along with the loss calculated during training/validation of the model. The respective crossplots along with comparisons of ground truth vs. artificial intelligence (AI)-predicted curves indicated that the model is capable of making accurate predictions with an error percentage between 0.2% and 0.6% on history-matching experimental data for all three tested ML techniques. This implies that the AI-based model exhibits better efficiency and reliability in determining Kr curves when compared to conventional methods. The developed ML models by no means replace the need to conduct drainage coreflooding or centrifuge experiments but act as an alternative to existing commercial platforms that are used to interpret experimental data to predict Kr curves. The two main advantages of the developed ML models are their capability of predicting Kr curves within a matter of a few minutes as well as with limited intervention from the end user. The results also include a comparison between classical ML approaches, shallow neural networks, and DNNs in terms of accuracy in predicting the final Kr curves. The research presented here is an extension of the state-of-the-art framework proposed by Mathew et al. (2021). However, the two main aspects of the current study are the application of deep learning for the prediction of Kr curves and the application of feature engineering. The latter not only reduces the training/testing time for the ML models but also enables the end user to obtain the final predictions with the least set of experimental data. The various models discussed in this research work currently focus on the prediction of Kr curves for drainage steady-state experiments; however, the work can be extended to capture the imbibition cycle as well.

Shale caprocks, often organic-rich, play a significant role in hydrogen sequestration, but their wettability is typically altered from water-wet to H2-wet due to the organic matter, compromising their sealing performance. Silica nanofluids can restore water-wet conditions, which is vital for effective containment of H2 in geological formations. However, laboratory experiments to test the effects of nanomaterials on wettability and interfacial tension (IFT) are resource-intensive and time-consuming. To address this challenge, data-driven machine learning (ML) models offer a promising alternative, allowing for the prediction of key UHS parameters—such as advancing and receding contact angles without the need for extensive laboratory testing. We have applied multiple ML models, including gradient boosting, extreme gradient boosting (XGboost), Catboost, random forest, and extra trees to predict the wettability of organic rich shale samples treated with silica nanofluids. The ML models were trained on a comprehensive dataset generated through laboratory experiments conducted under a wide range of pressure (0.5 – 1600psi) and temperature (298-323 K) conditions, using brine (1 wt.% KCl + 2 wt.% NaCl) and varying silica nanofluid concentrations (0.05–1.0 wt.%). Advanced visualization techniques, including swarm maps, box plots, and heatmap plots, were utilized to analyze the experimental dataset thoroughly. To enhance the generalization capabilities of the ML models, we employed Bayesian optimization for hyperparameter tuning, along with k-fold cross-validation and grid-search optimization techniques. Both statistical and graphical analyses were performed to show the reliability and performance of the models. The results demonstrated that the implemented ML models, particularly the XGboost and Catboost, accurately predicted the wettability behavior under various operating conditions. The training and testing average R² scores were above 0.998 and 0.949, respectively, confirming the high accuracy of the predictions. These findings highlight the reliability of the ML algorithms in predicting the complex interaction between shale, brine, and H2. Further investigation into the feature importance revealed that nanomaterials had the greatest influence on the wettability of the ternary system. The silica nanofluid concentrations played a key role in modifying wettability, with varying impacts on the receding contact angles, emphasizing the effect of nanomaterial treatment. The model's predictions were consistent with experimental results, suggesting that geological conditions, including pressure and temperature, have a profound influence on rock mineral wettability, directly impacting H2 geo-storage capacity. This study is the first to employ data-driven ML models to predict critical UHS parameters in organic-rich shales treated with silica nanofluids. The ability of the ML models to predict UHS parameters across a wide range of conditions provides a valuable tool for optimizing UHS system designs, offering a more efficient and scalable approach compared to traditional experimental methods.

Understanding the spatial distribution of soil organic carbon (SOC) content over different climatic regions will enhance our knowledge of carbon gains and losses due to climatic change. However, little is known about the SOC content in the contrasting arid and sub-humid regions of Iran, whose complex SOC–landscape relationships pose a challenge to spatial analysis. Machine learning (ML) models with a digital soil mapping framework can solve such complex relationships. Current research focusses on ensemble ML models to increase the accuracy of prediction. The usual ensemble method is boosting or weighted averaging. This study proposes a novel ensemble technique: the stacking of multiple ML models through a meta-learning model. In addition, we tested the ensemble through rescanning the covariate space to maximize the prediction accuracy. We first applied six state-of-the-art ML models (i.e., Cubist, random forests (RF), extreme gradient boosting (XGBoost), classical artificial neural network models (ANN), neural network ensemble based on model averaging (AvNNet), and deep learning neural networks (DNN)) to predict and map the spatial distribution of SOC content at six soil depth intervals for both regions. In addition, the stacking of multiple ML models through a meta-learning model with/without rescanning the covariate space were tested and applied to maximize the prediction accuracy. Out of six ML models, the DNN resulted in the best modeling accuracies, followed by RF, XGBoost, AvNNet, ANN, and Cubist. Importantly, the stacking of models indicated a significant improvement in the prediction of SOC content, especially when combined with rescanning the covariate space. For instance, the RMSE values for SOC content prediction of the upper 0–5 cm of the soil profiles of the arid site and the sub-humid site by the proposed stacking approaches were 17% and 9% respectively, less than that obtained by the DNN models—the best individual model. This indicates that rescanning the original covariate space by a meta-learning model can extract more information and improve the SOC content prediction accuracy. Overall, our results suggest that the stacking of diverse sets of models could be used to more accurately estimate the spatial distribution of SOC content in different climatic regions.

• ML models for predicting SCM concretes compressive strength developed • Multiple datasets devised from a global dataset were used for training • Multiple ML models used in conjunction with multiple datasets for best results • Accurate prediction results obtained for all SCM concrete types studied • Prediction uncertainty bounds established by conformal prediction analysis Supplementary cementitious materials (SCM) used as partial replacements of cement can reduce carbon emissions and construction costs. The amount and types of SCM used directly influence the compressive strength of concrete, which is a crucial indicator of concrete performance. However, predicting compressive strength is challenging for SCM-based concretes due to their complex compositions, especially when multiple types of SCM are used. This study used five machine learning (ML) models, namely artificial neural network (ANN), random forest (RF), extra trees (ET), extreme gradient boosting (XGB), and adaptive boosting (AdaBoost) to predict the 28-day compressive strength of SCM concretes incorporating fly ash (FA), silica fume (SF), and ground granulated blast furnace slag (GGBFS). Firstly, a global dataset comprising 1456 data points was organized into seven individual and six combined datasets for training of the five ML models. After this, the performances of the ML models’ predictions using individual and combined datasets were compared using root mean squared error (RMSE) and coefficient of determination (R 2 ) to identify the optimal ML model-dataset configurations for each type of SCM-based concrete. It is found that in general, XGB models developed using the combined datasets demonstrated superior prediction accuracy, achieving an R² value exceeding 0.8. Both Shapley Additive Explanation (SHAP) and partial dependence plots (PDPs) were employed to illustrate the effects of input variables on compressive strength. Finally, uncertainty quantification using the Jackknife method combined with a normalized nonconformity measure was employed to provide accurate uncertainty bounds for compressive strength predictions.

For effective management of water quantity and quality, it is absolutely essential to estimate the pollution level of the existing surface water. This case study aims to evaluate the performance of twelve machine learning (ML) models, including five boosting-based algorithms (adaptive boosting, gradient boosting, histogram-based gradient boosting, light gradient boosting, and extreme gradient boosting), three decision tree-based algorithms (decision tree, extra trees, and random forest), and four ANN-based algorithms (multilayer perceptron, radial basis function, deep feed-forward neural network, and convolutional neural network), in estimating the surface water quality of the La Buong River in Vietnam. Water quality data at four monitoring stations alongside the La Buong River for the period 2010–2017 were utilized to calculate the water quality index (WQI). Prediction performance of the ML models was evaluated by using two efficiency statistics (i.e., R2 and RMSE). The results indicated that all twelve ML models have good performance in predicting the WQI but that extreme gradient boosting (XGBoost) has the best performance with the highest accuracy (R2 = 0.989 and RMSE = 0.107). The findings strengthen the argument that ML models, especially XGBoost, may be employed for WQI prediction with a high level of accuracy, which will further improve water quality management.

A study on road accident prediction and contributing factors using explainable machine learning models: analysis and performance

Abstract. As air pollution is regarded as the single largest environmental health risk in Europe it is important that communication to the public is up to date and accurate and provides means to avoid exposure to high air pollution levels. Long- and short-term exposure to outdoor air pollution is associated with increased risks of mortality and morbidity. Up-to-date information on present and coming days' air quality helps people avoid exposure during episodes with high levels of air pollution. Air quality forecasts can be based on deterministic dispersion modelling, but to be accurate this requires detailed information on future emissions, meteorological conditions and process-oriented dispersion modelling. In this paper, we apply different machine learning (ML) algorithms – random forest (RF), extreme gradient boosting (XGB), and long short-term memory (LSTM) – to improve 1, 2, and 3 d deterministic forecasts of PM10, NOx, and O3 at different sites in Greater Stockholm, Sweden. It is shown that the deterministic forecasts can be significantly improved using the ML models but that the degree of improvement of the deterministic forecasts depends more on pollutant and site than on what ML algorithm is applied. Also, four feature importance methods, namely the mean decrease in impurity (MDI) method, permutation method, gradient-based method, and Shapley additive explanations (SHAP) method, are utilized to identify significant features that are common and robust across all models and methods for a pollutant. Deterministic forecasts of PM10 are improved by the ML models through the input of lagged measurements and Julian day partly reflecting seasonal variations not properly parameterized in the deterministic forecasts. A systematic discrepancy by the deterministic forecasts in the diurnal cycle of NOx is removed by the ML models considering lagged measurements and calendar data like hour and weekday, reflecting the influence of local traffic emissions. For O3 at the urban background site, the local photochemistry is not properly accounted for by the relatively coarse Copernicus Atmosphere Monitoring Service ensemble model (CAMS) used here for forecasting O3 but is compensated for using the ML models by taking lagged measurements into account. Through multiple repetitions of the training process, the resulting ML models achieved improvements for all sites and pollutants. For NOx at street canyon sites, mean squared error (MSE) decreased by up to 60 %, and seven metrics, such as R2 and mean absolute percentage error (MAPE), exhibited consistent results. The prediction of PM10 is improved significantly at the urban background site, whereas the ML models at street sites have difficulty capturing more information. The prediction accuracy of O3 also modestly increased, with differences between metrics. Further work is needed to reduce deviations between model results and measurements for short periods with relatively high concentrations (peaks) at the street canyon sites. Such peaks can be due to a combination of non-typical emissions and unfavourable meteorological conditions, which are rather difficult to forecast. Furthermore, we show that general models trained using data from selected street sites can improve the deterministic forecasts of NOx at the station not involved in model training. For PM10 this was only possible using more complex LSTM models. An important aspect to consider when choosing ML algorithms is the computational requirements for training the models in the deployment of the system. Tree-based models (RF and XGB) require fewer computational resources and yield comparable performance in comparison to LSTM. Therefore, tree-based models are now implemented operationally in the forecasts of air pollution and health risks in Stockholm. Nevertheless, there is big potential to develop generic models using advanced ML to take into account not only local temporal variation but also spatial variation at different stations.

Social determinants of health (SDOH) play a critical role in the onset and progression of chronic kidney disease (CKD). Despite the well-established role of SDOH, previous studies have not fully incorporated these factors in predicting CKD in Type 2 diabetes patients. To bridge this gap, this study aimed to develop and evaluate the machine learning (ML) models that incorporate SDOH to enhance CKD risk prediction in Type 2 diabetes patients. Data were obtained from the 2023 Behavioral Risk Factor Surveillance System (BRFSS), a national survey that collects comprehensive health-related data from adults across the United States. Missing data were addressed using the K-nearest neighbor imputation method, and the Synthetic Minority Oversampling Technique (SMOTE) was applied to balance class distributions. Potential predictive features were selected using correlation coefficient analysis. The dataset was partitioned into training (80%) and testing (20%) subsets, with a 3-fold cross-validation strategy applied to the training data. Seven ML models were developed for CKD risk prediction, including logistic regression (LR), decision tree (DT), K-nearest neighbor (KNN), random forest (RF), eXtreme Gradient Boosting (XGBoost), and an artificial neural network (ANN). Model performance was evaluated using multiple metrics, including the area under the receiver operating characteristic curve (AUROC), precision, recall, F1 score, accuracy, and false positive rate. The study included 19,912 Type 2 diabetes patients (weighted sample size: 818,878), among whom 2,924 (weighted 13.92%) had CKD, and 16,988 (weighted 86.08%) did not. Over half of the CKD group (50.4%) were aged 65 or older. The proportion of female patients was higher in both groups, comprising 53.8% of the CKD group and 50.5% of the non-CKD group. Among the ML models evaluated, the RF model demonstrated the highest predictive performance for CKD, with an AUROC of 0.89 (95% CI: 0.88 - 0.90), followed by the DT model (0.84, 95% CI: 0.83 - 0.85) and XGBoost (0.83, 95% CI: 0.82 - 0.84). The RF model achieved an accuracy of 0.81 (95%CI: 0.81 - 0.81), a precision of 0.79 (95%CI: 0.79 - 0.79), a recall of 0.85 (95%CI: 0.85 - 0.85), and an F1 score of 0.82 (95%CI: 0.82 - 0.82). Additionally, the RF model exhibited strong calibration, reinforcing its reliability as a predictive tool for CKD risk in individuals with Type 2 diabetes. The study findings underscore the potential of ML models, particularly the RF model, in accurately predicting CKD among individuals with Type 2 diabetes. This approach not only enhances the precision of CKD prediction but also highlights the importance of addressing social and environmental disparities in disease prevention and management. Leveraging ML models with SDOH can lead to earlier interventions, more personalized treatment plans, and improved health outcomes for vulnerable populations. The online version contains supplementary material available at 10.1007/s40200-025-01621-9.

Laser powder bed fusion (LPBF) is a widely used Additive Manufacturing (AM) process involving a high-powered laser to fuse metal powder and build up successive layers to create complex structures. Process parameter selection significantly impacts the dimensional characteristics of the melt pool morphology, including its depth and width, which is vital to the final print quality. Accurately predicting the melt-pool depth is critical for ensuring the quality of the final product. Various methods for different materials have been investigated, for example, thermal image analysis, analytical methods like scaling law, machine learning, and so on. However, most of the promising results are only studies for one material, and it is not necessarily fully applied to another material. In this paper, our study involves utilizing machine learning models to make predictions of melt-pool depth in the LPBF process and compare their performance to an analytical approach based on scaling law with Nickel alloys IN625 and IN718. We trained three different machine learning models which are Gaussian Process Regression (GPR), Support Vector Machines (SVM), and Neural Networks (NN), and evaluated their performance using R-squared error and Root Mean Squared Error (RMSE) against the performance of the analytical scaling law. Our results show that the machine learning models outperform the scaling law approach significantly. This study demonstrates the potential of machine learning for improving the accuracy of melt-pool depth prediction in LPBF and provides insights into the strengths and limitations of different machine learning models for this task.

Laser-based metal additive manufacturing (MAM), particularly laser powder bed fusion (LPBF) and laser directed energy deposition (L-DED), is a transformative technology enabling the production of complex, high-performance metal components with precision and minimal waste. However, its wider adoption is hindered by challenges in ensuring repeatability and consistency due to the complex, dynamic nature of the process. Closed-loop systems with in-situ monitoring and control have gained attention for quality assurance, where machine learning (ML) models are crucial for correlating sensor data with process state diagnosis and facilitating control actions. This review adopts an ML perspective to elucidate the role of ML in closed-loop control systems. It first outlines sensor data types and preprocessing methods used as ML datasets, then discusses roles and applications of ML models for in-situ monitoring, highlighting limitations and potential solutions. An ML-based closed-loop control framework is also presented, with emphasis on the integration of ML in the control component. Finally, future development directions of advanced ML approaches are envisioned. This review provides new insights into enhancing the role of ML models in laser-based MAM closed-loop control systems, serving as a crucial aid in the development of intelligent control systems.

BackgroundSarcopenia is a common muscle disorder in older adults, and its early identification and management in middle-aged populations are essential for ensuring a healthier later life. Detecting sarcopenia at an earlier stage may reduce the future burden on health care systems and enhance the quality of life in older adults. Machine learning (ML) models can evaluate large datasets, identify essential variables, and find complicated correlations between input variables. However, using ML models to detect sarcopenia remains an unsatisfied need.ObjectiveThis study aimed to develop and externally validate an ML model to predict sarcopenia risk among middle-aged adults using a nationally representative dataset.MethodsWe analyzed data from 1926 participants aged 40 to 64 years and enrolled in the 2022 Korea National Health and Nutrition Examination Survey (KNHANES). Sarcopenia was diagnosed and defined based on the 2019 Asian Working Group for Sarcopenia criteria, which incorporate both low muscle mass and reduced muscle strength. Muscle mass was assessed using bioelectrical impedance analysis with cutoffs of <7.0 kg/m² for men and <5.7 kg/m² for women. Muscle strength was measured via handgrip strength using a digital dynamometer with thresholds of <28 kg for men and <18 kg for women. Participants meeting both criteria were classified as those with sarcopenia. Four ML algorithms, random forest, support vector machine, extreme gradient boosting, and logistic regression, were used to identify risk factors of sarcopenia and predict its likelihood. The top-performing model was subsequently validated in an external cohort of 2247 middle-aged adults from the 2023 KNHANES. Model performance was assessed using the F2-score, area under the curve of a receiver operating characteristic curve, and sensitivity. All analyses were conducted using Python 3.13.2 (Python Software Foundation).ResultsAmong the 4 models, the logistic regression model demonstrated the strongest performance, yielding an area under the curve of 0.85, a sensitivity of 0.92, and an F2-score of 0.66. External validation using the 2023 KNHANES dataset confirmed the model’s robust performance, indicating its potential for widespread applications.ConclusionsThis study developed and externally validated an ML model that accurately identified sarcopenia in middle-aged adults. Leveraging data from a comprehensive national survey, our findings underscore the significance of early detection and customized interventions in midlife to mitigate sarcopenia risk and optimize long-term health outcomes.

Modeling of necking area reduction of carbon steel in hydrogen environment using machine learning approach