Fault detection in metallic structures requires a detailed and discriminative feature pool creation mechanism to develop an effective condition monitoring system. Traditional fault detection methods incorporate handcrafted features either from the time, frequency or time-frequency domains. To explore the salient information provided by the acoustic emission (AE) signals, a hybrid of feature pool creation and an optimal features subset selection mechanism is proposed for crack detection in a spherical tank. The optimal hybrid feature pool creation process is composed of two major parts: (1) extraction of statistical features from time and frequency domains, as well as extraction of traditional features associated with the AE signals; and (2) genetic algorithm (GA)-based optimal features subset selection. The optimal features subset is then provided to the k-nearest neighbor (k-NN) classifier to distinguish between normal (NC) and crack conditions (CC). Experimental results show that the proposed approach yields an average 99.8% accuracy for heath state classification. To validate the effectiveness of the proposed approach, it is compared to conventional non-linear dimensionality reduction techniques, as well as those without feature selection schemes. Experimental results show that the proposed approach outperforms conventional non-linear dimensionality reduction techniques, achieving at least 2.55% higher classification accuracy.