Analog Computing revisited: A fully analog and minimalistic Damage Detector for Ultrasonic Testing enabling Material-Integrated Structural Health Monitoring

Guided wave-based structural health monitoring (GWSHM) with onboard transducers offers significant potential for the early diagnosis of damage in engineering structures. However, the practical deployment of deep learning models is often hindered by the limited availability of labelled experimental data and the high computational cost of generating large-scale high-fidelity simulation datasets. This study presents a multifidelity transfer learning framework that integrates lightweight physics-based simulations, convolutional autoencoder (CAE)-based deep feature learning, a feed-forward neural network, and limited experimental measurements for accurate damage localisation and sizing in plate-like structures instrumented with piezoelectric transducers. A computationally efficient one-dimensional time-domain spectral element model is employed to generate a large synthetic dataset for pretraining, while transfer learning adapts the model to experimental domains using only a small amount of labelled data. The CAE-based transfer learning framework significantly outperforms its CNN-based counterpart in damage localisation accuracy. The model achieves excellent predictive performance with $R^2$ scores exceeding 0.93 for damage localisation and 0.99 for damage sizing. Its generalisation capability is demonstrated on previously unseen data, showing high prediction accuracy for damage scenarios not represented during pretraining or fine-tuning. The results establish the proposed framework as an accurate, computationally efficient, and practically viable solution for real-world GWSHM applications.

Reliable identification of railway wheel defects is important for safety and maintenance. This study develops a machine-learning-based diagnostic framework for multi-class defect identification using passive air-coupled ultrasonic acoustic emission signals. Data were collected from eleven full-scale railway wheelsets representing nine health states. Time- and frequency-domain features were evaluated using Kruskal-Wallis statistical testing and mutual-information analysis to identify the most discriminative indicators. A Random Forest classifier was then trained using the selected features with stratified 5-fold cross-validation. The model achieved a balanced accuracy of approximately 0.66 and a Macro-F1 score of 0.65 across the nine classes. Decay rate, kurtosis, skewness, and envelope low-frequency power emerged as the most influential features, while a compact subset of features retained most of the classification performance. The results demonstrate the feasibility of combining passive ultrasonic sensing, statistical feature selection, and supervised machine learning for non-contact railway wheel defect classification and provide a foundation for future field-deployable inspection systems.

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.