Structural Health Monitoring (SHM) is the automation of the condition assessment process of an engineered system. When applied to geometrically large components or structures, such as those found in civil and aerospace infrastructure and systems, a critical challenge is in designing the sensing solution that could yield actionable information. This is a difficult task to conduct cost-effectively, because of the large surfaces under consideration and the localized nature of typical defects and damages. There has been significant research efforts in empowering conventional measurement technologies for applications to SHM in order to improve performance of the condition assessment process. Yet, the field implementation of these SHM solutions is still in its infancy, attributable to various economic and technical challenges. The objective of this Roadmap publication is to discuss modern measurement technologies that were developed for SHM purposes, along with their associated challenges and opportunities, and to provide a path to research and development efforts that could yield impactful field applications.

Pressure mapping has garnered considerable interest in the healthcare and robotic industries. Low-cost and large-area compliant devices, as well as fast and effective computational algorithms, have been proposed in the last few years to facilitate distributed pressure sensing. One approach is to use electrical impedance tomography (EIT) to reconstruct the contact pressure distribution of piezoresistive materials. While tremendous success has been demonstrated, conventional algorithms may be unsuitable for real-time monitoring due to its computational demand and runtime. Moreover, the low resolution of reconstructed images is a well-known issue related to the regularization strategies typically employed for traditional EIT methods. Therefore, in this study, two different supervised machine learning (ML) approaches, namely, radial basis function networks and deep neural networks, were employed to efficiently solve the inverse EIT problem and improve the resolution of reconstructed pressure maps. The demonstration of high-resolution pressure mapping, specifically, for identifying pressure hotspots, was achieved using a carbon nanotube-based thin film integrated with foam.

Strain measurements are vital for monitoring the load-bearing capacity and safety of structures. A common approach is to affix strain gages onto structural surfaces. On the other hand, most aerospace, automotive, civil, and mechanical structures are painted and coated, often with many layers, prior to their deployment. There is an opportunity to design smart and multifunctional paints that can be directly pre-applied onto structural surfaces to serve as a sensing layer among their other layers of functional paints. Therefore, the objective of this study was to design a strain-sensitive paint that can be used for structural monitoring. Carbon nanotubes (CNT) were dispersed in paint by high-speed shear mixing, while paint thinner was employed for adjusting the formulation’s viscosity and nanomaterial concentration. The study started with the design and fabrication of the CNT-based paint. Then, the nanocomposite paint’s electromechanical properties and its sensitivity to applied strains were characterized. Third, the nanocomposite paint was spray-coated onto patterned substrates to form “Sensing Meshes” for distributed strain monitoring. An electrical resistance tomography (ERT) measurement strategy and algorithm were utilized for reconstructing the conductivity distribution of the Sensing Meshes, where the magnitude of conductivity (or resistivity) corresponded to the magnitude of strain, while strain directionality was determined based on the strut direction in the mesh.

Cellular lattice structures possess high strength-to-weight ratios suitable for advanced lightweight engineering applications. However, their quality and mechanical performance can degrade because of defects introduced during manufacturing or in-service. Their complexity and small length scale features make defects difficult to detect using conventional nondestructive evaluation methods. Here we propose a current injection-based method, electrical resistance tomography (ERT), that can be used to detect damaged struts in conductive cellular lattice structures with their intrinsic electromechanical properties. The reconstructed conductivity distributions from ERT can reveal the severity and location of damaged struts without having to probe each strut. However, the low central sensitivity of ERT may result in image artifacts and inaccurate localization of damaged struts. To address this issue, this study introduces an absolute, high throughput, conductivity reconstruction algorithm for 3D ERT. The algorithm incorporates a strut-based normalized sensitivity map to compensate for lower interior sensitivity and suppresses reconstruction artifacts. Numerical simulations and experiments on fabricated representative cellular lattice structures were performed to verify the ability of ERT to quantitatively identify single and multiple damaged struts. The improved performance of this method compared with classical ERT was observed, based on greatly decreased imaging and reconstructed value errors.

Information on the presence and location of cracks in civil structures can be precious to support operators in making decisions related to structural management and scheduling informed maintenance. This paper investigates the efficacy of supervised machine learning to solve the inverse electrical impedance tomography problem and to reconstruct the conductivity distribution of a piezoresistive sensing film. This film consists of a conductive paint applied onto structural components, and operators can use its conductivity distribution to identify crack sizes and locations in the underlying structure. A deep neural network is employed to reconstruct a dense conductivity distribution within the painted area by using only voltage measurements collected at sparse boundary locations. Since one of the most challenging aspects of using supervised learning tools for real-world applications is generating a representative training dataset, this paper presents a new approach to test the suitability of synthetic datasets built using a finite element model of the sensing film. Results are reported for four sensing specimens fabricated with two different techniques (i.e., using carbon nanotubes and graphene nanosheets, respectively). Crack-like damage is induced to the substrate of the sensing film and identified using the proposed machine learning technique. Promising results are obtained as compared to conventional methods.