Automated Rayleigh-Wave Nonlinear Acoustic Platform for Real-Time Fatigue Monitoring in Metallic Materials

This paper presents a fully automated platform for real-time monitoring of fatigue-induced microstructural changes in metallic materials, using Rayleigh surface waves and Laser Doppler Vibrometry (LDV). The system integrates ultrasonic excitation, non-contact optical sensing, and high-speed signal processing in a unified LabVIEW environment. Rayleigh waves are generated via a contact transducer, while LDV captures surface vibrations with sub-nanometric velocity resolution, ensuring repeatability and eliminating coupling variability. The software automates synchronization, deterministic data acquisition, filtering, FFT analysis, and extraction of nonlinear coefficients (β2, β3) at high execution rates without the need for post-processing. Experimental validation under cyclic loading revealed a clear sensitivity hierarchy: the Rayleigh wave velocity remained invariant, the acoustic attenuation responded gradually, while the nonlinear parameters exhibited the earliest and steepest response to fatigue damage, confirming their superiority as early-stage indicators. The system offers low-latency timing, long-term stability, and modular design, establishing a robust data-streaming foundation that can support future integration with digital twin frameworks and machine learning models. Furthermore, the acoustic findings were successfully cross-validated using Infrared Thermography, which confirmed the critical damage transition phase. This work bridges nonlinear acoustics and software automation, providing a scalable diagnostic solution for predictive maintenance within structural health monitoring systems.