Structural Health Monitoring of a Lamina in Unsteady Water Flow Using Modal Reconstruction Algorithms

Ensuring the structural integrity of mechanical components operating in fluid environments requires precise and reliable monitoring techniques. This study presents a methodology for reconstructing the full-field deformation of a flexible aluminium plate subjected to unsteady water flow in a water tunnel, using a structural modal reconstruction approach informed by experimental data. The experimental setup involves an aluminium lamina (200 mm × 400 mm × 2.5 mm) mounted in a closed-loop water tunnel and exposed to a controlled flow with velocities up to 0.5 m/s, corresponding to Reynolds numbers on the order of 104, inducing transient deformations captured through an image-based optical tracking technique. The core of the methodology lies in reconstructing the complete deformation field of the structure by combining a reduced number of vibration modes derived from the geometry and boundary conditions of the system. The novelty of the present work consists in the integration of the Internal Strain Potential Energy Criterion (ISPEC) for mode selection with a data-driven machine learning framework, enabling real-time identification of active modal contributions from sparse experimental measurements. This approach allows for an accurate estimation of the dynamic response while significantly reducing the required sensor data and computational effort. The experimental validation demonstrates strong agreement between reconstructed and measured deflections, with normalised errors below 15% and correlation coefficients exceeding 0.94, confirming the reliability of the reconstruction. The results confirm that, even under complex, time-varying fluid–structure interactions, it is possible to achieve accurate and robust deformation reconstruction with minimal computational cost. This integrated methodology provides a reliable and efficient basis for structural health monitoring of flexible components in hydraulic and marine environments, bridging the gap between sparse measurement data and full-field dynamic characterisation.