AccScience Publishing / IJAMD / Online First / DOI: 10.36922/IJAMD026310028
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ORIGINAL RESEARCH ARTICLE

Physics-guided machine learning for ultrasonic crack-depth quantification in laboratory rail specimens using laser ultrasonics

Faeez Masurkar1*
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1 The British University in Dubai, Dubai , United Arab Emirates
Received: 30 July 2026 | Revised: 4 September 2026 | Accepted: 11 September 2026 | Published online: 17 September 2026
© 2026 by the Author(s). This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution 4.0 International License ( https://creativecommons.org/licenses/by/4.0/ )
Abstract

Accurate quantification of crack depth is essential for ensuring the structural integrity and operational safety of railway infrastructure. Conventional ultrasonic inspection techniques primarily focus on defect detection and often require baseline measurements or expert interpretation, limiting their suitability for autonomous structural health monitoring. This study proposes a physics-guided machine learning (ML) framework for baseline-free ultrasonic crack-depth quantification in rail-track structures using ultrasonic guided-wave and data-driven regression models. Rayleigh-wave ultrasonic signals were acquired from 13 rail specimens, comprising three healthy specimens and ten specimens with crack depths ranging from 2 to 20 mm. Each specimen was tested 25 times, resulting in a database of 325 ultrasonic measurements. After signal preprocessing, nine physics-guided damage-sensitive features, including amplitude, energy, attenuation, arrival time, and wavelet-based descriptors, were extracted to characterize crack-induced changes in wave propagation. Four regression algorithms, namely Gradient Boosted Regression Trees (GBRT-LSBoost), Random Forest (RF), Support Vector Regression (SVR), and Gaussian Process Regression (GPR), were evaluated using independent test data and specimen-wise, grouped cross-validation. Model interpretability and robustness were further assessed through feature importance, permutation importance, feature ablation, correlation analysis, and uncertainty quantification. The results show that amplitude and attenuation-based features are the most influential predictors of crack depth, whereas time-of-flight and several wavelet features contribute marginally. Among the four nonlinear ML models, Random Forest achieved the best independent-test performance (R² = 0.961, RMSE = 1.610 mm), closely followed by GBRT-LSBoost (R² = 0.960, RMSE = 1.623 mm) which could be suitable for field deployment under complex and dynamic conditions. Notably, a peak-amplitude-only linear regression baseline achieved lower error (R² = 0.995, RMSE = 0.563 mm), demonstrating the strong approximately linear relationship between transmitted Rayleigh-wave amplitude and prescribed crack depth under the controlled laboratory conditions. The results demonstrate the feasibility of the proposed feature-level physics-guided regression framework under controlled laboratory conditions, while further validation using a larger number of independent specimens and naturally occurring service cracks is required before field deployment.

Graphical abstract
Keywords
Physics-guided machine learning
Ultrasonic guided waves
Rail-track structural health monitoring
Crack-depth quantification
Rayleigh wave ultrasonics
Non-destructive testing
Funding
None.
Conflict of interest
Faeez Masurkar is a Youth Editorial Board Member of this journal, but was not in any way involved in the editorial and peer-review process conducted for this paper, directly or indirectly. The author declares there are not any potential conflicts or competing interests with any institutes, organizations or agencies that might influence the integrity of results or objective interpretation of the submitted work.
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International Journal of AI for Materials and Design, Electronic ISSN: 3029-2573 Print ISSN: 3041-0746, Published by AccScience Publishing