Defects occurring during the welding process of metal structural components directly affect their overall strength, which is crucial to the load-bearing capacity and durability of the components. This signifies the importance of accurate measurement and assessment of weld strength. However, traditional non-destructive testing methods such as ultrasonic and non-contact camera inspection have certain technical limitations. In response to these issues, this paper analyzes the detection principle of weld strength, revealing that weld defects reduce the effective area of the structural bearing section and cause stress concentration around them. Through repeated experimental data analysis of samples, strain distribution data along the one-dimensional direction caused by defects such as slag inclusion and porosity were obtained. Experimental results show that this method can identify defect types in welds, including slag inclusion, porosity, and unevenness, and accurately measure the location and size of defects with a precision of 0.64 mm, achieving qualitative analysis of weld defects. Additionally, by deploying distributed optical fiber sensors (DOFS) at different vertical distances along the weld direction, the propagation law of stress induced by different types of weld defects on samples was thoroughly analyzed. This further validates the advantages of this method in weld strength detection, including high spatial resolution, high sensitivity, and non-destructive measurement.

The precise evaluation of micro-crack sizes and locations is crucial for the safe operation of structures. Traditional detection techniques, however, suffer from low spatial resolution, making it difficult to accurately locate micrometer-scale cracks. A method and experimental study were proposed in this paper for identifying and locating micro-cracks using optical fiber strain sensing based on OFDR to address this issue. The feasibility of this method for micro-crack detection was verified by the combination of a polyimide-coated sensing optical fiber (PISOF) and tight sheath sensing optical fiber (TSSOF). A calculation method for micro-crack widths based on distributed optical fiber strain curves was established, and the test results of different optical fibers were compared. Through multiple verification experiments, it was found that the strain peak curves of both fiber types could accurately locate micro-cracks with a precision of 1 mm. Additionally, the crack widths could be obtained by processing the distributed strain curves using a computational model, enabling the accurate capture of micro-crack characteristics at the 10 μm level. A strong linear relationship was observed between the optical fiber stretching length and the crack width. Notably, the relative error in calculating the crack width from the strain curve of PI fiber was very small, while a linear relationship existed between the maximum strain value of the TSSOF and the crack width, allowing for the calculation of the crack width based on the maximum strain value. This further validated the feasibility of the method designed in this paper for the analysis of micro-crack characteristic parameters.