SeaCausal-FL: Federated Fuzzy Causal Learning for Maritime IoT Fault Diagnosis and Counterfactual Reasoning

Reliable marine-engine fault diagnosis in maritime IoT is challenged by distributed data ownership, heterogeneous fault distributions, and continuously changing operating conditions. This paper proposes SeaCausal-FL, a federated fuzzy causal learning framework that combines a shared temporal diagnostic path with mechanism-conditioned causal reasoning. An interval type-2 fuzzy layer represents uncertain and overlapping operating mechanisms, while each mechanism is associated with a physics-constrained structural causal model. Before aggregation, locally learned mechanisms are aligned using operating context, causal structure, and conditional intervention-response signatures. Model parameters are then aggregated according to sample, class, mechanism, and mechanism-class evidence instead of client sample size alone. The learned structural equations further support interval counterfactual reasoning through abduction, action, and prediction. Experiments on a marine-engine fault dataset and a real-data-calibrated semi-synthetic causal benchmark show that SeaCausal-FL achieves an average F1 score of 87.07% across four client partitions, with AUROC and AUPRC of 98.98% and 94.81%, respectively. It also maintains strong performance under unseen loads and fault-type omission during training. On the causal benchmark, SeaCausal-FL reaches an Edge-F1 of approximately 0.58 and an Edge-AUPRC of 0.68, reduces coefficient RMSE to about 0.14, and provides favorable counterfactual estimation and intervention decisions.