High-resolution weld defect detection with RSU-MLP and dynamic kernel supervision

The challenges posed by high-resolution X-ray images of weld defects—including fuzzy features, multi-scale variability, small targets, and sample imbalance—create significant obstacles for accurate defect localization. Traditional deep learning methods typically emphasize global image characteristics, often neglecting local and multi-scale information, which leads to the inaccurate detection of small defects. To address this issue, we propose a novel high-resolution weld defect detection method called RSU-MLP. This method combines the RSU-MLP network with multi-scale feature extraction technology to effectively capture both local and global image features. Additionally, we design a dynamic kernel adaptive segmentation head based on a hybrid extended convolutional attention mechanism, which adaptively adjusts the receptive field size of the convolutional kernel, thereby enhancing detection capabilities for defects of varying scales. Furthermore, an in-depth supervision mechanism is introduced to monitor and learn defects at different levels of the network, leading to improved detection performance. Experimental results on real high-resolution welding datasets demonstrate that the proposed method achieves promising results in welding defect detection. Compared to traditional approaches, this method provides more accurate detection and identification of various welding defects, achieving DICE and Jaccard scores of 75.97% and 64.01%, respectively. This represents the best performance, demonstrating both robustness and generalization capabilities. Consequently, it offers a reliable automated detection method for producing high-quality welded products.