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A novel structural health monitoring approach consisting of guided ultrasonic waves, acoustic emission, and digital image correlation, as well as real-time and postmortem analyses, was implemented to monitor and quantify crack growth in Al 2024 compact tension specimens, designed, and precracked according to ASTM E647-08. Tensile loads were applied according to ASTM E1290-08. Guided ultrasonic waves were generated with pulses centered at three different frequencies and were recorded using piezoelectric transducers. Guided ultrasonic waves were also modeled using finite element wave propagation models. The same transducers were further used for online acoustic emission monitoring. A digital image correlation system continuously monitored the crack growth and provided full-field surface strains. The application of this integrated structural health monitoring approach resulted in reliable damage detection and quantified crack growth measurements. In addition, a novelty detector based on the Mahalanobis distance was implemented in a data fusion scheme to assess the extent of damage. The reported results constitute a proof-of-concept investigation of a novel structural health monitoring approach based on the combination of real-time optical and acoustic nondestructive testing.

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