EAAI Journal 2026 Journal Article
Accurate detection and characterization of sub-millimeter cracks using nonlinear ultrasonics-informed parallel multi-branch convolutional neural network
- Lu Wang
- Zhengpan Qi
- Xiangyan Ding
- Ning Hu
- Xiaoyang Bi
- Han Zhang
- Libin Zhao
Conventional ultrasonic testing struggles to inspect sub-millimeter cracks and identify multiple characteristics. To overcome these limitations, this study proposes a parallel multi-branch convolutional neural network (PMCNN) to simultaneously and accurately detect the depth, length, and orientation of sub-millimeter cracks. The artificial intelligence (AI) innovation lies in the PMCNN's branch-specific kernels and cross-task isolation layers that effectively decouple overlapping nonlinear ultrasonic signals. First, ultrasonic non-destructive testing was performed on micro-crack specimens to obtain essential data for verifying both the finite element (FE) model and PMCNN. Subsequently, an FE model was established to systematically analyze the coupling effects of depth, length, and orientation on the signals and to generate a comprehensive dataset for PMCNN training. The primary engineering application is the provision of an effective solution for quantitative micro-crack assessment in complex operational environments through experimental validation with practical inspection signals. Results reveal that while harmonic amplitudes correlated with individual parameter variations, their sensitivity significantly decreases under multiparameter conditions. Interpretability analysis confirms the distinct feature selectivity of each branch network, while a hybrid data training strategy maintains robust accuracy (above 90 %) under noisy conditions. Experimental validation demonstrates that the proposed method achieves stable and reliable performance, bridging advanced AI techniques with practical structural health monitoring needs.