3-DUSSS: 3-Dimensional Ultrasonic Self Supervised Segmentation

This study introduces a novel self-supervised learning approach for volumetric segmentation of defect indications captured by phased array ultrasonic testing data from Carbon Fiber Reinforced Polymers (CFRPs). By employing this self-supervised method, defect segmentation is achieved automatically without the need for labelled training data or examples of defects. The approach has been tested using artificially induced defects, including back-drilled holes and Polytetrafluoroethylene (PTFE) inserts, to mimic different defect responses. Additionally, it has been evaluated on stepped geometries with varying thickness, demonstrating impressive generalization across various test scenarios. Minimal preprocessing requirements are needed, with no removal of geometric features or Time-Compensated Gain (TCG) necessary for applying the methodology. The model's performance was evaluated for defect detection, in-plane and through-thickness localisation, as well as defect sizing. All defects were consistently detected with thresholding and different processing steps able to remove false positive indications for a 100% detection accuracy. Defect sizing aligns with the industrial standard 6 dB amplitude drop method, with a Mean Absolute Error (MAE) of 1.41 mm. In-plane and through-thickness localisation yielded comparable results, with MAEs of 0.37 and 0.26 mm, respectively. Visualisations are provided to illustrate how this approach can be utilised to generate digital twins of components.

3-Dimensional residual neural architecture search for ultrasonic defect detection

This study presents a deep learning methodology using 3-dimensional (3D) convolutional neural networks to detect defects in carbon fiber reinforced polymer composites through volumetric ultrasonic testing data. Acquiring large amounts of ultrasonic training data experimentally is expensive and time-consuming. To address this issue, a synthetic data generation method was extended to incorporate volumetric data. By preserving the complete volumetric data, complex preprocessing is reduced, and the model can utilize spatial and temporal information that is lost during imaging. This enables the model to utilise important features that might be overlooked otherwise. The performance of three architectures were compared. The first two architectures were hand-designed to address the high aspect ratios between the spatial and temporal dimensions. The first architecture reduced dimensionality in the time domain and used cubed kernels for feature extraction. The second architecture used cuboidal kernels to account for the large aspect ratios. The evaluation included comparing the use of max pooling and convolutional layers for dimensionality reduction, with the fully convolutional layers consistently outperforming the models using max pooling. The third architecture was generated through neural architecture search from a modified 3D Residual Neural Network (ResNet) search space. Additionally, domain-specific augmentation methods were incorporated during training, resulting in significant improvements in model performance for all architectures. The mean accuracy improvements ranged from 8.2% to 22.4%. The best performing models achieved mean accuracies of 91.8%, 92.2%, and 100% for the reduction, constant, and discovered architectures, respectively. Whilst maintaining a model size smaller than most 2-dimensional (2D) ResNets.

GANs and alternative methods of synthetic noise generation for domain adaption of defect classification of Non-destructive ultrasonic testing

This work provides a solution to the challenge of small amounts of training data in Non-Destructive Ultrasonic Testing for composite components. It was demonstrated that direct simulation alone is ineffective at producing training data that was representative of the experimental domain due to poor noise reconstruction. Therefore, four unique synthetic data generation methods were proposed which use semi-analytical simulated data as a foundation. Each method was evaluated on its classification performance of real experimental images when trained on a Convolutional Neural Network which underwent hyperparameter optimization using a genetic algorithm. The first method introduced task specific modifications to CycleGAN, to learn the mapping from physics-based simulations of defect indications to experimental indications in resulting ultrasound images. The second method was based on combining real experimental defect free images with simulated defect responses. The final two methods fully simulated the noise responses at an image and signal level respectively. The purely simulated data produced a mean classification F1 score of 0.394. However, when trained on the new synthetic datasets, a significant improvement in classification performance on experimental data was realized, with mean classification F1 scores of 0.843, 0.688, 0.629, and 0.738 for the respective approaches.