Deep Learning Autoencoders for Fast Fourier Transform-Based Clustering and Temporal Damage Evolution in Acoustic Emission Data from Composite Materials

Structural health monitoring (SHM) in fiber-reinforced polymer (FRP) composites is essential to ensure safety and reliability during service, particularly in critical industries such as aerospace and wind energy. Traditional methods of analyzing Acoustic Emission (AE) signals in the time domain often fail to accurately detect subtle or early-stage damage, limiting their effectiveness. The present study introduces a novel approach that integrates frequency-domain analysis using the fast Fourier transform (FFT) with deep learning techniques for more accurate and proactive damage detection. AE signals are first transformed into the frequency domain, where significant frequency components are extracted and used as inputs to an autoencoder network. The autoencoder model reduces the dimensionality of the data while preserving essential features, enabling unsupervised clustering to identify distinct damage states. Temporal damage evolution is modeled using Markov chain analysis to provide insights into how damage progresses over time. The proposed method achieves a reconstruction error of 0.0017 and a high R-squared value of 0.95, indicating the autoencoder’s effectiveness in learning compact representations while minimizing information loss. Clustering results, with a silhouette score of 0.37, demonstrate well-separated clusters that correspond to different damage stages. Markov chain analysis captures the transitions between damage states, providing a predictive framework for assessing damage progression. These findings highlight the potential of the proposed approach for early damage detection and predictive maintenance, which significantly improves the effectiveness of AE-based SHM systems in reducing downtime and extending component lifespan.