Real‑time crack detection is essential for the safety and longevity of critical infrastructure. This paper presents a novel Wave‑Tune framework that combines multi‑modal wave propagation (ultrasonic, Lamb, and guided electromagnetic waves) with an adaptive signal‑processing pipeline to continuously monitor, locate, and quantify cracks as they evolve. A closed‑loop “tuning” algorithm adjusts excitation parameters (frequency, mode, amplitude) on‑the‑fly based on instantaneous feedback from a sparse sensor network, maximizing sensitivity while minimizing false alarms. Laboratory experiments on aluminum alloy plates, carbon‑fiber‑reinforced polymer (CFRP) coupons, and a full‑scale steel bridge segment demonstrate sub‑millimeter crack resolution and detection latency under 30 ms. Finite‑element (FE) and wave‑field simulations validate the adaptive strategy and reveal the underlying physics of wave‑crack interaction across a broad frequency spectrum. The Wave‑Tune approach opens a pathway toward autonomous structural health monitoring (SHM) systems capable of proactive maintenance decisions.

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Finite‑element (ABAQUS + COMSOL) simulations of a 10 mm surface crack in the aluminum plate revealed:

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Guided wave testing uses waves that propagate along the surface of a material or through a waveguide. These waves are sensitive to changes in the material's properties, such as cracks or corrosion. By analyzing the guided wave's propagation patterns, it is possible to detect and characterize cracks in real-time.

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