Integrated Laser Scanning and Image-Based Topology Optimization Techniques for Detection and Quantification of Visible and Subsurface Structural Defects
Reliable characterization of structural defects requires methods capable of resolving both directly observable surface damage and damage that is not visible from the inspected surface. This study presents two complementary non-contact, vision-based approaches for the detection and quantitative characterization of defects in structural components. The first approach employs high-resolution laser scanning to generate three-dimensional (3D) point clouds of damaged steel specimens. Comparative processing of measured and reference point clouds is used to localize damaged regions, quantify geometric loss, and transfer the measured defect geometry to a finite element representation. The second approach combines full-field surface deformation measurements obtained using three-dimensional digital image correlation (3D-DIC) with finite element model updating and topology optimization. In this inverse framework, measured surface response is used to infer subsurface abnormalities through their influence on the spatial distribution of structural response. Experimental steel-beam specimens containing controlled smooth defects and randomly distributed defects are used to evaluate the approaches. Comparisons with milling-based ground-truth measurements demonstrate that both methods can identify and quantify defect geometry, while providing complementary information for visible and subsurface damage assessment. The combined framework establishes a pathway toward high-fidelity, non-contact structural condition assessment and model updating for components with complex and irregular damage.