Deep Learning Empowered Structural Health Monitoring and Damage Diagnostics for Structures with Weldment via Decoding Ultrasonic Guided Wave

Welding is widely used in the connection of metallic structures, including welded joints in oil/gas metallic pipelines and other structures. The welding process is vulnerable to the inclusion of different types of welding defects, such as lack of penetration and undercut. These defects often initialize early-age cracking and induced corrosion. Moreover, welding-induced defects often accompany other types of mechanical damage, thereby leading to more challenges in damage detection. As such, identification of weldment defects and interaction with other mechanical damages at their early stage is crucial to ensure structural integrity and avoid potential premature failure. The current strategies of damage identification are achieved using ultrasonic guided wave approaches that rely on a change in physical parameters of propagating waves to discriminate as to whether there exist damaged states or not. However, the inherently complex nature of weldment, the complication of damages interactions, and large-scale/long span structural components integrated with structure uncertainties pose great challenges in data interpretation and making an informed decision. Artificial intelligence and machine learning have recently become emerging methods for data fusion, with great potential for structural signal processing through decoding ultrasonic guided waves. Therefore, this study aimed to employ the deep learning method, convolutional neural network (CNN), for better characterization of damage features in terms of welding defect type, severity, locations, and interaction with other damage types. The architecture of the CNN was set up to provide an effective classifier for data representation and data fusion. A total of 16 damage states were designed for training and calibrating the accuracy of the proposed method. The results revealed that the deep learning method enables effectively and automatically extracting features of ultrasonic guided waves and yielding high precise prediction for damage detection of structures with welding defects in complex situations. In addition, the effectiveness and robustness of the proposed methods for structure uncertainties using different embedding materials, and data under noise interference, was also validated and findings demonstrated that the proposed deep learning methods still exhibited a high accuracy at high noise levels.