This work presents the introduction and experimental investigation of an active-sensing acousto-ultrasound structural health monitoring approach for damage size quantification based on piezoelectric sensors/actuators mounted on multiple seemingly identical structural components. The objective of this work is to determine how reliable the damage diagnostics can be from one component to another similar (nominally identical) component using surface-mounted PZT (lead zirconate titanate) sensors/actuators, and also to evaluate how sensitive a sensor network configuration in terms of the number of sensors/actuators is with respect to its detection reliability. Extensive crack growth experiments on multiple identical coupons outfitted with the same sensor network configuration under cyclic loads were conducted to assess the damage quantification reliability from one coupon to another using the same diagnostic algorithm. The results of the study indicate that the crack size estimates obtained from the active-sensing structural health monitoring system can vary within the population of identical structural components (coupons), but the difference in quantifying damage among coupons decreases with the increase in the number of sensors and actuators used, that is, wave propagation paths. Furthermore, it is shown that the diagnostic results in terms of damage quantification converge with the increase in the number of sensors. The results of the study indicate that the diagnostic approach using a multi-path sensor network can reduce the damage quantification error from one component to another within a “hotspot” configuration (damage location is known or suspected a priori). Finally, the results of this study indicate that the more wave propagation paths used in the diagnostic active-sensing algorithm, the more reliable the damage quantification results are, provided that the same sensor network is used and installed at nominally identical locations for all coupons.
