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Towards CyberSHM: autonomous acousto-ultrasonic health monitoring of operational composite structures

Lead Research Organisation: CARDIFF UNIVERSITY
Department Name: Sch of Engineering

Abstract

Continuous monitoring of in-service safety-critical structures for real-time assessment of their operational health is receiving significant attention and is a highly topical area of research. This is can be attributed, among others, to the following two factors.
i) The rapid evolution of next-generation complex composite structures and their ubiquitous use as lightweight structures in several industries ranging from aerospace to offshore/onshore energy infrastructure, automotive and nuclear industry.
ii) The significant advancement of automation within a data-rich environment and the immense appetite of industries to leverage its benefits for transforming their traditional, often interventionist, practices.

Significant research investment into next-generation complex composite structures (such as the ongoing EPSRC grant EP/T011653/1) and their rapid uptake in industrial usage has brought to the fore concerns and challenges around monitoring of these structures. Investigations into the susceptibility of these structures to subtle, barely visible damages (like hidden debonding, fibre/matrix-cracking) reveal that the latter can significantly jeopardize the structural integrity and can lead to catastrophic failures. The recent multiple catastrophic accidents in the passenger flights involving aeroplanes manufactured by the world's erstwhile largest planemaker has rightly enhanced the scrutiny on the safety, serviceability and suitability of such structures for public use. This is coupled with objectives for employing greener and sustainable structures (to meet the global emissions target as pledged in the Paris Climate Agreement 2016) and reducing operational costs associated with their inspection and maintenance without compromising on safety.

Concurrently, with a paradigmatic shift towards industrial internet of things within Industry4.0 with ubiquitous, pervasive computing coupled with advanced sensing and communication technologies, it has become a necessity to develop structural health monitoring (SHM) solutions of safety-critical engineering structures which are abreast of, can reap the benefits of and are able to fit seamlessly into this intelligent, data-rich environment of automation.

The proposal is aimed at fundamental scientific investigation into and the technological implementation of monitoring of lightweight composite structures to bridge the gap between the conceived futuristic vision of SHM and the existing interventionist practices of evaluating structural health. The objective of this project is to address the challenge of real-time acousto-ultrasonic monitoring (akin to "listening for damages" and/or changes in structural response) and online damage identification of operational structures using a multi-pronged approach with the key components being -
a) physics-driven underlying model or digital equivalent of structural ultrasonic waveguides behaviour under various operational/ambient conditions,
b) the extraction, synchronization and utilization of structural acoustic fingerprints of damage events (such as tool drop, delamination, cracks) as collected by the onboard sensory network for data-driven training and classification of damage events and
c) a real-time damage identification toolbox (identifying the location, type and severity) which is both data-driven (in-situ sensor data) and model-informed (physics-based understanding of structural waveguides) to give quantified metrics of incipient damage along with their estimated confidence.

The project takes the novel approach of assimilating physics-based characterization structural acoustic characteristics with data from hybrid passive-active acousto-ultrasonic monitoring and interrogation of the monitored structures for a cyberphysical monitoring or CyberSHM of in-service structures.
 
Description The CyberSHM project comprises a work package focused on developing edge computing devices that can seamlessly integrate into smart structures. These devices are equipped with the capability to collect and transmit in-situ data at the edge of the structure. Traditionally, this process has necessitated digital signal processing platforms with substantial footprints, posing challenges in deploying them for real-time monitoring.

The project has successfully developed the CyberSHM platform, which enables PC-on-chip devices to monitor and interrogate operational structures using guided waves. These devices process signals at the edge and deploy trained machine learning algorithms for critical decision-making processes. A demonstrator of this technology has been developed and is currently being utilised for testing structural health monitoring, yielding promising results.

Furthermore, a toolbox has been developed to predict the dispersion characteristics of thin-walled laminated composite waveguides with elastic and geometrical singularities, which represent damage. This toolbox is undergoing experimental validation. It is being deployed in a physics-informed approach for damage identification, where experimental data-driven models for mapping acoustic-ultrasonic waves to damage parameters are complemented by physics-based predictions of dispersion. The research conducted in this area has been recognised with an international award for the best research paper at the largest aerospace conference globally (SciTech 2025). Additionally, the researcher has received invitations for keynote lectures at international conferences, including the 6th International Conference on Health Monitoring of Civil & Maritime Structures.
Exploitation Route In collaboration with industry partners involved in this project, the project team has implemented the CyberSHM systems for real-time autonomous structural health monitoring environments. As a result, the team has achieved top-quality journal publications in reputable journals and research paper awards. Moving forward, one of the project's objectives is to develop a physics-informed ultrasonic testing device that can be utilised by industry practitioners and academic partners for autonomous monitoring of operational structures.

The CyberSHM technology developed within the project is poised for implementation at Airbus' scheduled in-house wing testing facility. The project will further develop the CyberSHM product through entrepreneur fellowships and proof-of-concept funding from UKRI. This initiative aims to demonstrate the economic impact of the developed technology on the burgeoning market for structural testing in the civil, transportation, aerospace, and automobile sectors.
Sectors Aerospace

Defence and Marine

Construction

Digital/Communication/Information Technologies (including Software)

Energy

Transport

 
Description The research findings have a direct impact on industrial practice in structural health monitoring and prognosis. The project's impact can be realised through the following: • The development of tools presented to industrial partners (Airbus and Mistras). • The planned implementation of the CyberSHM tool for aircraft wing testing at Airbus. • The potential for developing a spin-off with support from UKRI (such as an entrepreneur fellowship and proof of concept) for IP protection and bringing the developed solutions to market. The research findings have substantially enhanced the global reputation of Cardiff University in this field. The research outcomes have garnered significant international recognition, including the Best Structures Paper Award at the largest global aerospace conference in the world (SciTech 2025). Additionally I have been • invited to deliver the keynote speech at the 6th International Conference on Health Monitoring of Civil & Maritime Structures. • appointed as an associate editor for the ASME (The American Society of Mechanical Engineers) Journal of Non-Destructive Evaluation both of which demonstrates the researchers emergence as an international rising leader in this field. The findings of the project has been used for widening participation program of Cardiff University, such as with Community Gateway Partnership, by participating in public engagement events, particularly aimed at encouraging uptake of STEM subjects amongst school students in communities (like Grangetown project) with low representation in UK higher education. • I have delivered a public engagement event under the Museum After Dark banner at the National Museum Cardiff. Here I planned and led a demonstration called Sounds & Bridges where acoustic footprints of structures were demonstrated to members of the public. The big demonstration was made possible with the assistance of my team of PhD students and PDRAs. • I have organised and represented Cardiff School of Engineering in the Grange Careersfair week with a team of academics and student ambassadors to further the equality-diversity-inclusivity objectives of Cardiff School of Engineering in March 2022 and 2025. I delivered a lecture along with two academic members to facilitate widening participation by showcasing the findings and impact of the CyberSHM project in practical engineering applications. The student ambassadors have highlighted the scope for students to pursue a career in STEM and the opportunities that exist at Cardiff School of Engineering.
First Year Of Impact 2024
Sector Aerospace, Defence and Marine,Communities and Social Services/Policy,Education,Transport
Impact Types Societal

 
Description Knowledge Transfer Partnerships
Amount £279,943 (GBP)
Funding ID KTP012935 
Organisation Innovate UK 
Sector Public
Country United Kingdom
Start 08/2021 
End 08/2024
 
Description SmartExpertise
Amount £111,884 (GBP)
Funding ID 82504 
Organisation Government of Wales 
Sector Public
Country United Kingdom
Start 01/2022 
End 12/2022
 
Description Wales-Quebec joint call for proposals
Amount £4,300 (GBP)
Funding ID RES40869 
Organisation Government of Wales 
Sector Public
Country United Kingdom
Start 11/2021 
End 03/2023
 
Title A Deep Learning Model For Autonomous Damage Identification/Classification in Composites 
Description A Deep Learning Model is developed for autonomous damage (e.g., acoustic emission source, breathing debond) Identification/Classification in Composites 
Type Of Material Improvements to research infrastructure 
Year Produced 2023 
Provided To Others? No  
Impact A Deep Learning Model is developed for autonomous damage (e.g., acoustic emission source, breathing debond) Identification/Classification in Composites 
 
Title Edge-computing based SHM & NDE Setup 
Description Developing an Edge-computing based Structural Health Monitoring Setup for robust and real-time monitoring of aerospace composites using Acoustic Emission and Guided Wave propagation 
Type Of Material Improvements to research infrastructure 
Year Produced 2023 
Provided To Others? No  
Impact The Structural Health Monitoring Setup will provide robust and real-time monitoring of aerospace composites 
 
Title Semi-analytical Guided Wave Dispersion Model for Damaged Composites 
Description Developed a robust Semi-analytical Guided Wave Dispersion Model for Damaged Composites 
Type Of Material Improvements to research infrastructure 
Year Produced 2022 
Provided To Others? No  
Impact A robust Semi-analytical Guided Wave Dispersion Model is developed for healthy and damaged Composites 
 
Title CyberSHM 
Description The CyberSHM project includes a segment dedicated to the creation of sleek edge computing devices that can seamlessly integrate into smart structures. These devices are capable of collecting, processing, and transmitting data on-site, without the need for large digital signal processing platforms. The traditional approach of using such platforms has proven challenging for real-time monitoring due to their bulky nature. To address this, the project has developed the CyberSHM platform, where PC-on-chip devices are able to monitor and analyze operational structures using guided waves. These devices are equipped to process signals on the edge and deploy trained machine learning algorithms for crucial decision-making. A demonstrator for this platform has been created and will undergo further improvements during the next phase of the project. 
Type Of Material Computer model/algorithm 
Year Produced 2024 
Provided To Others? No  
Impact The CyberSHM devices has the potential to make a significant impact in the field of structural health monitoring. Real-time monitoring of structures can be done more efficiently and effectively, without the challenges posed by bulky equipment. This technology allows for enhanced data analysis, leading to more accurate and timely decisions regarding the structural health of monitored systems. The ability to collect, process, and transmit data on-site enables quicker response times and improved overall structural safety. This research has the potential to revolutionize the way in which structures are monitored and maintained, ultimately leading to increased efficiency, cost savings, and improved structural integrity. Furthermore, the development of a demonstrator and the planned iterative improvements in the next phase of the project demonstrate the dedication to practical implementation and ensuring real-world impact. 
 
Title Deep Learning for damage identification 
Description A fully data-driven deep learning approach for identification of damage based on their acoustic emission characteristics have been developed which is capable of using AI. 
Type Of Material Data analysis technique 
Year Produced 2023 
Provided To Others? Yes  
Impact A paper has been published on this which has already gathered several academic citations since last year. 
 
Title eSAFE model 
Description The eSAFE model enables analysis on dispersion of waveguides for any general layup of thinwalled laminated waveguides which has daamges characterised geometrical or elastic property changes across the laminar direction. This is a first of its kind of model which can study the effect of damage and anomalies on the dispersion characteristics of waveguides. 
Type Of Material Computer model/algorithm 
Year Produced 2024 
Provided To Others? No  
Impact The academic impact of this model has been realised by two journal papers under preparation. The results have been presented at academic conferences and is being showcased to industry partners in the project. 
 
Description Collaboration with Airbus 
Organisation Airbus Group
Department Airbus Operations
Country United Kingdom 
Sector Private 
PI Contribution Airbus has participated in joint research meetings and has provided input by steering the direction of the project and providing industrially relevant ideas for the project.
Collaborator Contribution Airbus has participated in a research seminars for discussing the CyberSHM research plan and collaboration paths with the project partners. They are providing in-kind input to the project by steering the research output into industrially relevant outcomes.
Impact Presentations have delivered from both sides (Cardiff & Airbus) for discussing the possible collaboration paths
Start Year 2022
 
Description Collaboration with Mistras 
Organisation Airbus Group
Department Airbus Operations
Country United Kingdom 
Sector Private 
PI Contribution A close collaboration is being undertaken with Mistras in this CyberSHM project. Mistras is actively involved in sharing knowledge about structural health monitoring trends and requirements from an industry perspective.
Collaborator Contribution Mistras is providing samples of decommissioned wind turbine blade sections which are being used in the research project. The blade sections will be tested for the performance of the CyberSHM toolboxes being developed in the project. Mistras being a leader in the field of SHM is providing inputs on the sensor hardware suitable for field testing. Their contribution to the project is in-kind and they participate in research steering committee meetings.
Impact The collboration with Mistras has resulted in 1 journal article published in Composite Structures. The data collected for this paper were done with the instrumentation supplied by Mistras and used for the CyberSHM toolbox performance testing.
Start Year 2022
 
Description Collaboration with Mistras 
Organisation Mistras Group Ltd
Country United Kingdom 
Sector Private 
PI Contribution A close collaboration is being undertaken with Mistras in this CyberSHM project. Mistras is actively involved in sharing knowledge about structural health monitoring trends and requirements from an industry perspective.
Collaborator Contribution Mistras is providing samples of decommissioned wind turbine blade sections which are being used in the research project. The blade sections will be tested for the performance of the CyberSHM toolboxes being developed in the project. Mistras being a leader in the field of SHM is providing inputs on the sensor hardware suitable for field testing. Their contribution to the project is in-kind and they participate in research steering committee meetings.
Impact The collboration with Mistras has resulted in 1 journal article published in Composite Structures. The data collected for this paper were done with the instrumentation supplied by Mistras and used for the CyberSHM toolbox performance testing.
Start Year 2022
 
Description Collaboration with Mistras 
Organisation Stanford University
Country United States 
Sector Academic/University 
PI Contribution A close collaboration is being undertaken with Mistras in this CyberSHM project. Mistras is actively involved in sharing knowledge about structural health monitoring trends and requirements from an industry perspective.
Collaborator Contribution Mistras is providing samples of decommissioned wind turbine blade sections which are being used in the research project. The blade sections will be tested for the performance of the CyberSHM toolboxes being developed in the project. Mistras being a leader in the field of SHM is providing inputs on the sensor hardware suitable for field testing. Their contribution to the project is in-kind and they participate in research steering committee meetings.
Impact The collboration with Mistras has resulted in 1 journal article published in Composite Structures. The data collected for this paper were done with the instrumentation supplied by Mistras and used for the CyberSHM toolbox performance testing.
Start Year 2022
 
Description Collaboration with Mistras 
Organisation University of Sherbrooke
Country Canada 
Sector Academic/University 
PI Contribution A close collaboration is being undertaken with Mistras in this CyberSHM project. Mistras is actively involved in sharing knowledge about structural health monitoring trends and requirements from an industry perspective.
Collaborator Contribution Mistras is providing samples of decommissioned wind turbine blade sections which are being used in the research project. The blade sections will be tested for the performance of the CyberSHM toolboxes being developed in the project. Mistras being a leader in the field of SHM is providing inputs on the sensor hardware suitable for field testing. Their contribution to the project is in-kind and they participate in research steering committee meetings.
Impact The collboration with Mistras has resulted in 1 journal article published in Composite Structures. The data collected for this paper were done with the instrumentation supplied by Mistras and used for the CyberSHM toolbox performance testing.
Start Year 2022
 
Description Collaboration with Polish Academy of Sciences - IMP PAN 
Organisation Institute of Fluid Flow Machinery
Country Poland 
Sector Public 
PI Contribution We have started a structured collaboration with Prof Wieslaw Ostachowicz and his research team in the Mechanics of Intelligent Structures Department at the Polish Academy of Sciences - IMP PAN, Gdansk, Poland. Through this collaboration, we planned research visits to conduct some specific experiments at IMP PAN using their state of the art environmental chamber, FBG-systems and ultrasonic interrogator. The collaboration is academic in nature and the group is making in-kind contribution to the project.
Collaborator Contribution The academic partnership has been very fruitful for the project to exchange knowledge. Prof Ostachowicz group has collaborated with us for exploring new sensor technologies for CyberSHM. The collaboration has produced joint journal publication in Composite Structures, Conference publication , Conference Presentations, Organised Special Session in the EWSHM 2022
Impact • The collaboration has resulted in 2 journal publications • Organised Special Session in the EWSHM 2022. EWSHM is amongst the largest structural health monitoring conferences in Europe and our team in collaboration with Prof Ostachowicz organised the largest special session in this conference - "Machine learning and modelling in structural health monitoring" • submitted extended abstract for the IWSHM conference 2023 to take place in Stanford University.
Start Year 2021
 
Description Collaboration with Stanford University 
Organisation Stanford University
Country United States 
Sector Academic/University 
PI Contribution We are exploring opportunities for collaboration with Stanford University's Prof F K Chang's research group for collaborative work on SHM in structures under environmentally extreme conditions which has applications in aerospace and renewable sector. The collaboration is academic in nature. We would be participating in the IWSHM 2023 conference organised by Prof FK Chang's group and would deliver talks at the host university.
Collaborator Contribution Towards developing a structured research collaboration, we will be attending the IWSHM 2023 conference organized by Prof F.K. Chang and his team at the University of Stanford and discussing the possible joint research activities. The collaborative work is scheduled to be undertaken towards the latter half of the project.
Impact Submitted an abstract to the IWSHM 2023, will participate in the IWSHM 2023 conference and discuss the possible research collaborations with Stanford
Start Year 2023
 
Title CyberSHM 
Description A sleek edge and cloud computing platform has been developed which combines the physics-based model for acousto-ultrasonic techniques in damage detection. This software is a collection of tools which allows - * data collection for training AI models to map signal features to damage parameters and online deployment of this trained model for real-time monitoring * material and degradation identification based on physics-informed Bayesian wave mode reconstruction * automated rapid interrogation of structures over a wide frequency band with on-edge signal processing * fully integrated with IoT for remote autonomous monitoring 
Type Of Technology Physical Model/Kit 
Year Produced 2025 
Impact The advanced CyberSHM platform will be implemented within Airbus' in-house testing facility, significantly enhancing testing overhead, data processing and management, and decision-making capabilities. This initiative will yield substantial economic benefits for Airbus' extensive testing programs, thereby augmenting their competitiveness and time-to-market for emerging technologies. The CyberSHM platform represents a pioneering innovation in the acousto-ultrasonic testing market. It has been developed and commercialised with the support of entrepreneurial fellowships and proof-of-concept funding from the UK Research and Innovation (UKRI). This development has the potential to evolve into a spin-off venture from the academic sector, with applications spanning diverse sectors including civil, transportation, aerospace, and energy. 
 
Description Grangetown Careers & Role Model week 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Public/other audiences
Results and Impact This event which was a recent initiative aimed at widening participation in higher education, specifically targeting local communities with historically low rates of university enrollment. The event, organized by the Grange Community gateway team, invited me to participate in the event from Cardiff School of Engineering (ENGIN). Such initiatives aligns with the institution's commitment to equality, diversity, and inclusivity. By engaging with students from minority ethnic backgrounds, the initiative sought to address the barriers these communities face in accessing higher education, particularly in STEM fields.

Event Overview

The event featured a series of interactive stalls designed to engage STEM students and the general public. Attendees were provided with information brochures detailing the UCAS application process, various career options, and job opportunities within the engineering sector. A key component of the event was a 30-minute presentation delivered by myself, which introduced potential career pathways for STEM students in engineering. This presentation aimed to inspire and inform attendees about the diverse opportunities available within the field.

Feedback from participants indicated a significant increase in interest in pursuing studies within ENGIN. This positive response was communicated to both the organizing team and the Grange Careers group, highlighting the effectiveness of the event in stimulating interest among local students.

Despite the success of the event, several challenges remain in the pursuit of widening participation among minority ethnic communities in the UK. While some of these can be cultural and socio-economic factors, we wanted to address awareness and information gaps, institutional barriers and lack of lack of representation of minority ethnic students within higher education institutions.

Conclusion

The participation in the event represents a crucial step towards addressing the challenges faced by minority ethnic communities in accessing higher education. By fostering engagement with local students and providing valuable information about career pathways in STEM, the initiative has the potential to inspire a new generation of engineers. However, it is essential to continue addressing the underlying barriers that hinder participation. Ongoing collaboration with former graduates and community organizations will be vital in developing strategies that effectively widen participation and create a more inclusive educational environment. Moving forward, it is imperative that universities remain committed to their equality, diversity, and inclusivity agendas, ensuring that all students, regardless of their background, have the opportunity to succeed in higher education.
Year(s) Of Engagement Activity 2025
 
Description Public Engagement - Grange Careers & Role Model Week 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Public/other audiences
Results and Impact Demonstrated the Mechanical Engineering research activities, 'Sound & Bridges' and Inspired school children in Engineering Education
Year(s) Of Engagement Activity 2022
 
Description Public Engagement Event - Museum After Dark, Cardiff 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Schools
Results and Impact Demonstrated the CyberSHM team research activities, 'Sound & Structures' with hands-on experiments to 200+ school children and other general public.
Year(s) Of Engagement Activity 2023