A Multi-Fidelity Convolutional Autoencoder-Transfer Learning Framework for Guided-Wave-Based Damage Diagnosis Using Large Simulated and Limited Experimental Datasets

Guided-wave structural health monitoring enables damage localization in composite plates using sparse networks of bonded piezoelectric transducers. However, supervised localization remains weakly constrained when measurements are available from only a limited set of damage locations. Because exhaustive spatial coverage is impractical, models trained at observed locations may generalize poorly to unseen regions. We propose WaveGraphNet, an inverse-forward graph-learning framework for guided-wave damage localization in carbon-fiber-reinforced polymer (CFRP) plates. The sensing network is represented as a graph, with transducers as nodes and measured pitch-catch paths as edges. The inverse branch uses order-invariant message passing and a geometry-constrained decoder to map path-wise energy deviations to a damage coordinate. An independently trained forward branch predicts the energy-deviation pattern associated with a candidate coordinate. At test time, gradients propagated through the forward branch update only the inverse-predicted coordinate to reduce the discrepancy between the measured and predicted response patterns. The framework is evaluated on the OGW-1 benchmark using three spatial hold-out splits in which complete damage regions are excluded from training. Comparisons include non-graph and graph-learning baselines together with the training-free Reconstruction Algorithm for Probabilistic Inspection of Damage (RAPID). Under the validation-selected settings, refined WaveGraphNet achieves the lowest reported test mean absolute error on all three splits. Refinement reduces the standalone localization error by 23.6 percent-67.9 percent, with an average relative reduction of 50.4 percent. These results demonstrate that learned forward-response consistency can improve guided-wave localization under limited spatial training coverage.

Structural health monitoring (SHM) has emerged as an essential tool for ensuring the integrity and reliability of critical engineering structures, particularly in aerospace applications. Since each sensing technology has its limitations, the fusion of different modalities enables capturing a more complete picture of inhomogeneous materials, like composites. However, effective multisensor data fusion in SHM is often hindered by heterogeneous sensing modalities that operate at disparate sampling frequencies and acquisition intervals. To address these challenges, this paper proposes a Transformer-based data fusion framework that integrates multisensor data streams from piezoelectric transducer (PZT) capturing ultrasonic guided wave signals and fiber Bragg grating (FBG) sensors for strain measurements. By incorporating an attention-mechanism visualization, the proposed framework enables transparent, multitask learning for both health indicator (HI) prediction and damage localization. The framework was experimentally validated using aircraft composite structures subjected to compression-compression fatigue cyclic loading. For HI prediction, the framework consistently achieved a mean absolute error (MAE) and root mean squared error (RMSE) below 0.1, representing a nearly 60% performance improvement over single-sensor approaches (PZT or FBG alone) and baseline deep learning models. For damage localization, the model demonstrated the highest accuracy, maintaining an MAE and RMSE below 0.0465 and 0.1571, respectively. These results demonstrate that the proposed Transformer-based data fusion framework significantly outperforms single-source models and state-of-the-art deep learning models in both HI prediction and damage localization accuracy.

Vibration-based damage identification in civil infrastructure is a challenging, ill-posed inverse problem due to measurement noise, sparse sensor arrays, and environmental variability. While deep learning is powerful for system identification, deterministic approaches lack reliable uncertainty quantification and can yield physically inconsistent results. This work proposes a robust probabilistic Scientific Machine Learning (SciML) framework: a physics-informed Gaussian copula variational autoencoder (PI-GCVAE) for structural health monitoring (SHM). First, we eliminate the need for data-driven surrogates by embedding a differentiable numerical eigenvalue solver directly into the VAE architecture. This ensures that latent space samples satisfy the governing equations of structural dynamics, reducing the trainable parameter space and improving generalization. Second, we replace the conventional independence assumption of latent variables with a Gaussian copula. This model captures complex, physics-dependent spatial cross-correlations between adjacent structural elements, defining feasible solutions while accounting for inherent system variability and measurement errors. Third, compared with alternatives such as Gaussian mixtures, our copula-based VAE provides an efficient distributional model for high-dimensional, strongly correlated latent spaces. We validate the approach using a synthetic dataset of a simply supported bridge subjected to various damage scenarios and corrupted with stochastic Gaussian noise. Synthetic data enables exhaustive validation against ground-truth stiffness values unavailable in practice. Results demonstrate that the PI-GCVAE accurately recovers the true posterior distribution, achieving 77.2% coverage. The proposed framework provides a reliable, scalable tool for early-stage damage diagnosis in operating bridges.