Identification of Location and Geometry of Invisible Internal Defects in Structures using Deep Learning and Surface Deformation Field

On‐site inspection of invisible subsurface defects in multiscale structural materials by conventional nondestructive testing (NDT) methods, such as X‐ray and ultrasound, requires complex sample preparation and data acquisition processes. Moreover, the inspected area is very small. Herein, a simple, inexpensive, and ultrasensitive NDT method for identifying and classifying the geometries of subsurface defects using commercial cameras, digital image correlation software, and object detection (OD) algorithms is developed. Three OD algorithms—Faster region‐based convolutional neural network (Faster R‐CNN), Mask R‐CNN, and you‐only‐look‐once (YOLO)v3—are evaluated for their ability to locate defects and identify defect geometries. Specifically, bounding boxes of two sizes (large and small) are applied to the regions of defect‐induced perturbations in strain tensors, which serve as virtual representatives of invisible subsurface defects. The performance of the proposed approach is validated on test datasets of known and unknown defect types. The experimental results confirm that the proposed approach can effectively utilize the surface deformation field information to accurately and reliably locate and identify subsurface defects. The method is nondestructive and low cost, enables real‐time detection, is robust against noise‐dominated deformation fields, and can be applied to various structural deformations. The method is therefore suitable for multiscale structural health monitoring and characterization of internal defects in materials.