Hello, I'm

Xijia Zhao

Ph.D. Candidate in Electrical Engineering

Case Western Reserve University

About Me

I am a Ph.D. candidate in Electrical Engineering at Case Western Reserve University, expected to graduate in August 2027. My research aims to build an end-to-end generalizable AI framework for industrial automation and robotic systems in three connected stages:

1 · Learn

Scalable and interpretable representations from large-scale data.

Self-supervised learning, interpretable AI

2 · Deploy

ML models across edge–cloud architectures.

Edge AI, IIoT

3 · Evolve

Continuously, as unseen data and conditions emerge after deployment.

Continual learning, federated learning

I worked on site at General Motors for six months, validating my pretext-training framework for inline laser-welding monitoring and delivering it to internal customers in manufacturing. The framework is now being adapted to more manufacturing processes. I am also working to commercialize EdgeSense, an edge–cloud AI system for industrial monitoring developed from my research.

Engineering Experience

General Motors

Feb 2026 – Jul 2026

Visiting Scientist of AI, Manufacturing R&D · On-site

  • Developed a pretext-training framework for inline laser-weld monitoring of EV battery cells, leveraging process metadata as weak supervision to learn from large-scale production signals with limited defect labels
  • Conducted scaled training across multiple GPUs on Azure clusters and evaluated the learned representations on downstream process-identification tasks
  • Delivered the framework and documentation to the manufacturing pipeline team; others have since used it to extend the approach to additional manufacturing processes

National Science Foundation I-Corps

Feb 2025 – May 2025

Entrepreneurial Lead · Remote

  • Led customer discovery, market validation, and business-model development for an edge–cloud AI system for industrial machine monitoring
  • Engaged with engineers, technical experts, and managers to identify industry needs and shape product development

General Motors

Jan 2024 – Aug 2024

Visiting Student, Research Collaboration · Remote

  • Developed Vision Transformer models for inline anomaly detection in battery laser welding
  • Presented a seminar on explainable AI approaches to manufacturing-process monitoring

University of Kentucky

Sep 2021 – Aug 2022

Undergraduate Research · On-site

  • Built a compact data-acquisition and edge-analytics system, integrating high-frequency sensing, data communication, and on-device neural-network inference

Research Projects

Feature-guided Interpretable Continual Learning Across Data Modalities

Ongoing Ph.D. research

Developing an interpretable training framework that helps the model disentangle concepts from the data, so it can identify and protect true knowledge while adapting to out-of-distribution data. Expected to generalize to both time-series and image data.

Continual Learning Interpretable AI Out-of-Distribution Time-Series & Vision

Interpretability Analysis of Vision-Language-Action Robot Policies

NeurIPS 2026 Main Track

Investigated the internal mechanisms of six VLA models (80M–7B parameters) with interpretability methods across 394,000+ rollout episodes on four benchmarks. Showed that visual representations strongly influence action generation and that learned motor programs are tied to scene coordinates rather than task semantics. Released Action Atlas, an interactive explorer of the learned representations.

Robotics VLA Models Mechanistic Interpretability Causal Interventions

On-Device Continual Self-Supervised Learning for Machine Condition Monitoring

IEEE Internet of Things Journal (in revision); U.S. provisional patent

Designed an edge-computing node for real-time condition monitoring of rotating machinery. Implemented continual self-supervised learning entirely on the microcontroller within 3 MB of memory, without cloud-based model updates.

Edge Computing On-Device Training Continual Learning IIoT

Hierarchical Self-Supervised Learning from Unlabeled Industrial Data

J. Manufacturing Systems 2025; J. Manufacturing Processes 2026

Developed multi-level contrastive learning frameworks (MoCo- and DINO-style) to learn from unlabeled factory data for both welding images and multichannel photodiode signals. Combining labeled lab data with unlabeled plant data improved transfer to defect classification and weld-quality prediction.

Self-Supervised Learning Contrastive Learning MoCo DINO

Transfer Learning for Virtual Process Sensing in Resistance Spot Welding

Manufacturing Letters 2025

Co-developed a transfer-learning-enhanced Transformer that estimates in-process weld quantities from available signals, serving as a digital twin that reduces the need for direct measurement.

Transformer Transfer Learning Virtual Sensing Digital Twin

Publications

* equal contribution

Journal Articles

In rev.

Zhao, X., Wang, P.

"How Should the Edge Adapt: Designing Reliable On-Device Continual Self-Supervised Learning for Condition Monitoring"

IEEE Internet of Things Journal, in revision.

In rev.

Zhou, Q.*, Sotubadi, V.*, Zhao, X.*, Ghassemi, H., Pour, M., Ma, J., Rinker, T., Huemiller, E., Wang, P. E.

"Toward Foundational Manufacturing Surrogates: Physics-Informed Machine Learning for Welding and Additive Manufacturing Across Geometries, Materials, and Processes"

Manuscript for Journal of Manufacturing Systems, in revision.

2026

Sotubadi, V., Hosseinzadeh, A., Ghassemi, H., Pour, M. M., Ma, J., Zhao, X., Bracey, J. T., Carlson, B. E., Wang, P. E.

"Harnessing Unlabeled Plant Data and Labeled Lab Data for Enhanced Quality Prediction in Laser Welding"

Journal of Manufacturing Processes, 157, pp. 1015–1034.

2025

Zhao, X., Ghassemi-Armaki, H., Carlson, B., Wang, P.

"Unleashing the Power of Unlabeled Plant Data: A Hierarchical Contrastive Learning Framework for Dynamic Manufacturing Process Monitoring"

Journal of Manufacturing Systems, 83, pp. 483–493.

2025

York, E., Zhao, X., Ghassemi, H., Carlson, B., Wang, P.

"Transfer Learning-Enhanced Transformer for Virtual Process Sensing in Resistance Spot Welding"

Manufacturing Letters, 45, pp. 13–16.

2025

Wang, P., Ghassemi, H., Pour, M., Zhao, X., Ma, J., Sattari, K., Carlson, B.

"Applicable and Generalizable Machine Learning for Intelligent Welding in Automotive Manufacturing"

Welding in the World, pp. 1–36.

Conference Papers

2026

Grant, B.*, Zhao, X.*, Wang, P.

"Not All Features Are Created Equal: A Mechanistic Study of Vision-Language-Action Models"

Advances in Neural Information Processing Systems (NeurIPS), Main Track. arXiv:2603.19233. Earlier version: ICLR 2026 Workshop on Multimodal Intelligence.

2024

Zhao, X., Kershaw, J., Pour, M., Ma, J., Ghassemi, H., Carlson, B., Wang, P.

"Efficient and Generalizable Machine Learning for Inline Defect Detection in Battery Laser Welding"

International Conference on Precision Engineering (ICPE). Sendai, Japan.

2024

Zhao, X., Wang, P.

"A Deployable Edge Computing Solution for Machine Condition Monitoring"

IEEE International Instrumentation and Measurement Technology Conference (I2MTC). Glasgow, United Kingdom, pp. 1–6.

Patents

2026

Pour, M., Sotubadi, V., Zhao, X., et al.

"Laser Welding Signal Analysis System and Method"

U.S. patent application, General Motors, filed May 2026.

2026

Wang, P., Zhao, X.

"Edge Computing Models for Apparatus Monitoring"

U.S. Provisional Patent Application No. 63/955,650, Case Western Reserve University, filed Jan 2026.

Pending

"Transformer-Based Multi-Level Contrastive Learning for Multi-Scale Welding Signal Representation"

General Motors internal patent disclosure, in process.

Education

Ph.D.

Electrical Engineering

Case Western Reserve University

Aug 2023 – Aug 2027 (expected)

Exchange

Electrical Engineering

University of Kentucky

2021 – 2023

B.S.

Electrical Engineering

Beijing University of Technology

2019 – 2023

Technical Skills

Machine Learning Methods

Self-Supervised Learning Contrastive Learning (MoCo, DINO) Continual Learning Neural Operators (FNO, GINO) Physics-Informed ML Causal Interventions Interpretable Representation Learning

Manufacturing & Sensing

Inline Process Inspection Laser-Weld Quality Monitoring Resistance-Spot-Weld Monitoring Vibration / Photodiode / Vision Sensing Signal Processing Anomaly & OOD Detection Rare-Event Detection Thermal-Simulation Surrogates

Embedded & Systems

Edge Computing On-Device Training on MCUs Docker Multi-GPU Training (PyTorch DDP) LSF Azure AWS

Programming

Python PyTorch C C++ LaTeX

Languages & Interests

Mandarin (native) English (fluent) Basketball Guitar Saxophone