Automated classification of subsurface impact damage in thermoplastic composites using depth-resolved terahertz imaging and deep learning

Reliable detection of barely visible impact damage is critical to ensure the structural integrity of composite components in service, particularly in safety-critical applications such as pressure vessels and transportation systems. This study presents a solution for detecting such damage in woven glass fiber-reinforced thermoplastic composites using terahertz (THz) time-of-flight tomography and convolutional neural networks. THz provides non-contact, non-ionizing, high-axial-resolution imaging of subsurface and back-surface damage, addressing key limitations of surface-based inspection methods. While THz imaging alone may not always permit conclusive damage identification, we bridge this gap by training neural network classifiers on depth-resolved THz B-scan images using ground truth from co-located X-ray micro-computed tomography. Among several pretrained architectures tested via transfer learning, DenseNet-121 exhibits the highest accuracy. The model remains robust even when trained on truncated B-scans excluding surface indentation features, confirming its ability to detect structural anomalies located internally or on the back surface. This is particularly relevant for applications where back-side access is not feasible. Experimental validation is performed on impacted glass-fiber-reinforced thermoplastic coupons prepared in accordance with ASTM D7136, with damage severity quantified through force–displacement data and micro-tomographic analysis. Labeling for supervised learning conforms to acceptance criteria from industrial standards for composite pressure vessels (ASME BPVC Section X, CGA C-6.2), ensuring regulatory alignment and enabling deployment in quality control workflows. The proposed method minimizes the need for expert interpretation or secondary validation and offers direct applicability to in-service inspection and manufacturing quality control.