Deep predictions and transfer learning for simulation-driven structural health monitoring based on guided waves

Simulation-driven structural health monitoring (SHM) is crucial for enhancing the safety and reliability of structures. Its primary aim is to utilize numerical simulations to design efficient SHM systems, reducing costs while maintaining effectiveness. However, challenges arise due to disparities between simulations and physical measurements, stemming from uncertainties, noise, and simplifications. These challenges also extend to SHM methods using machine learning, particularly deep neural networks (DNNs). This paper bridges the gap between DNNs trained on simulated data and real-world experiments by investigating three transfer learning (TL) techniques: feature augmentation, direct fine-tuning, and boosting-based fine-tuning. The focus is on guided wave damage interaction coefficients (WDICs) as damage-sensitive features, modeled by DNNs for damage identification in thin plates, commonly found in aerospace structures like aircraft fuselages. This classification task compares measured and predicted WDICs in a common guided wave SHM configuration with one actuator and three sensors. Training and extensive testing datasets are generated using advanced finite element simulations and laser Doppler vibrometer experiments. The study demonstrates that TL techniques significantly enhance DNN prediction accuracy and improve damage identification performance for untrained scenarios compared to purely simulation-based DNNs. Among the TL approaches explored, feature augmentation with appropriate activation functions and boosting-based fine-tuning yield the most promising results. Using four out of twelve TL datasets, feature augmentation reduces the simulation-based mean absolute percentage error from 46.80% to 35.98% and increases coefficient of determination R2 values from 0.02 to 0.72. With six TL datasets and a boosting-based fine tuning, the mean absolute percentage error decreases from 47.42% to 35.20%, maintaining similar R2 values. While TL substantially enhances prediction accuracy, its impact on damage identification is slightly less pronounced, with improvements in relative classification accuracy by approximately 5% compared to simulation-based DNNs. These findings highlight the efficacy of TL techniques for damage identification in thin plates using WDICs and DNNs, emphasizing the influence of TL training and DNN model variations. Furthermore, they showcase the potential of TL methods to enhance DNN performance in future SHM applications, particularly emphasizing the promise of feature augmentation and boosting.