Supervised and Unsupervised AI-Driven Structural Health Monitoring Framework for Additively Manufactured Metal Components

Structural health monitoring (SHM) of additively manufactured (AM) small and complex components is investigated using a sensor-based signal processing and machine-learning framework. Guided-wave responses acquired from piezoelectric transducers are analyzed to evaluate the performance of sweep-sine and pulse excitation signals, as well as the influence of infill patterns, part geometry, and defect type on system reliability. Test specimens, including dogbone structures and a simulated rocket-nozzle component, were fabricated using AM, and nonstationary guided-wave signals were recorded and processed. Time–frequency signal representations (scalograms) were generated using the Continuous Wavelet Transform (CWT). Convolutional Neural Networks (CNNs) and Gaussian Mixture Models (GMMs) were employed for supervised classification and unsupervised clustering, respectively. Sweep-sine excitation consistently yielded higher classification accuracy, with CNN analysis achieving near-perfect performance and GMM clustering demonstrating improved group separability. In contrast, pulse excitation revealed transient signal features associated with wave interactions, including reflections, mode conversion, and scattering, highlighting its potential for complementary signal-based diagnostics. Importantly, the proposed hybrid supervised–unsupervised learning framework enables the quantification of previously unseen intermediate load states, demonstrating strong adaptability and generalizability beyond the conditions represented in the training data.