Video-Based Prediction of In-Flight Particle Characteristics in Atmospheric Plasma Spraying
Authors: Abhijeet Praveen, Sareh Soleimani, Cormac Cureton, Aman Sidhu, Kintak Raymond Yu, Cristian Cojocaru, Narges Armanfard
Organizations: Department of Electrical and Computer Engineering, McGill University, Montreal, QC H2X 2G6, Canada · Mila – Quebec AI Institute, Montreal, QC H2S 3H1, Canada · National Research Council of Canada, Boucherville, QC J4B 6G4, Canada
Abstract
Atmospheric plasma spraying (APS) is a widely used coating process in which in-flight particle temperature and velocity strongly influence coating quality. However, these particle characteristics are difficult to monitor continuously during operation, motivating the development of non-invasive data-driven diagnostic methods. In this work, we investigate the predictive potential of high-speed video observations of the plasma plume for estimating in-flight particle characteristics in APS. We introduce three different video-derived feature representations and evaluate them using Tabular Prior-Data Fitted Networks (TabPFN), convolutional neural networks (CNN), and classical regression baselines including Random Forest, Gradient Boosting, Support Vector Regression, and XGBoost. Experiments are conducted using grouped leave-one-out cross-validation on 126 labeled pre- and post-spray video recordings from 63 APS spray runs. Across the engineered feature experiments, TabPFN achieves the most consistent performance for temperature prediction, reaching R2 = 0.86 using the combined feature representation. CNN models particularly perform stronger for velocity prediction, achieving R2 of 0.81. In addition, we evaluate models operating directly on raw video frames using pretrained CNNs and find that the highest performance is achieved by a pretrained CNN with a regression head with R2 of 0.90 and 0.82 for temperature and velocity, respectively. The results demonstrate that video-derived plume information provides a promising and scalable foundation for non-invasive APS diagnostics and real-time process monitoring.
Inferring continuum models directly from video is hampered by two facts: the recorded field is uncalibrated image intensity rather than a physical state, and direct numerical differentiation of noisy frames is unstable. We develop a video-to-PDE pipeline that converts grayscale recordings of an ink plume into a normalised scalar field u(x,y,t), isolates a bulk drift v(t) from intrinsic spreading via the intensity-weighted centroid, and identifies an effective transport law by weak-form sparse regression. Conditioning, threshold-sweep and random-centre diagnostics show that overcomplete libraries are strongly collinear; the search is therefore restricted to compact gradient-based libraries. Coefficients are refined by an inverse physics-informed network and recalibrated against forward rollouts, with a chronological block bootstrap quantifying uncertainty. The selected reduced model ut+v(t)⋅∇u=9.005∣∇u∣2+0.666Δu outperforms advection--diffusion baselines on held-out frames, retains a positive Laplacian coefficient, and admits a Cole--Hopf reduction to a linear advection--diffusion equation. The framework demonstrates that uncalibrated visual data can yield compact, predictive and structurally interpretable continuum models when discovery, calibration and uncertainty are treated as distinct stages.
Nuclear fusion has made significant progress in recent years and is expected to become one of the most important pathways to addressing global energy challenges. This paper focuses on observing plasma using visible-light cameras, analyzing its spatio-temporal motion cues, and predicting the two-dimensional spatial distribution of light intensity, aiming to provide a foundational basis for future scientific experiments using deep neural networks. Specifically, we propose Delta-InvFormer, a novel backbone network centered on a differential Transformer. The key insight is that by taking consecutive video frames as input, we can better capture the dynamics of the plasma. Moreover, spatial and temporal differential self-attention effectively mitigates interference from noisy signals, ensuring high-quality feature extraction. These features are then fused into a compact and informative representation, which is fed into a decoder network to predict the distribution. Based on real experimental data collected from the Experimental Advanced Superconducting Tokamak (EAST) large-scale scientific facility, our results demonstrate that the proposed model not only significantly accelerates traditional methods for distribution prediction but also achieves competitive reconstruction accuracy. The source code of this paper will be released on https://github.com/Event-AHU/OpenFusion
Designing spray nozzles requires predicting how geometry shapes transient two-phase breakup, but high-fidelity volume-of-fluid (VOF) simulations with adaptive mesh refinement (AMR) are too expensive for iterative design exploration. Standard surrogate models are also challenged by this setting because both the liquid--gas interface and the underlying adaptive discretization evolve across time and geometries. We introduce a geometry-conditioned latent surrogate trained on 797 two-phase nozzle simulations that addresses this by encoding the AMR cell-density field, rather than the full multi-channel flow state, as a compact proxy for where the solver concentrates resolution. From this representation, the model reconstructs transient density evolution and nozzle geometry, and a lightweight second stage recovers the remaining flow variables. On held-out simulations, the method accurately captures key interface dynamics while reducing inference time to 0.045 seconds per trajectory, corresponding to a speed-up of more than 6×104 relative to Basilisk CFD. These results suggest that AMR refinement structure can serve as a compact and learnable representation for geometry-conditioned surrogate modeling of transient two-phase flows.
Julius H Ramlau, Friedrich Hastedt, Tolga Birdal +3