Collaborative Optimization of High-Resolution Representation and Miss-Sensitive Supervision for Aero-Engine Micro-Crack Detection

Aero-engine blades operate under extreme conditions involving high temperature, pressure, rotational speed, and cyclic loads, making them susceptible to surface defects such as micro-cracks. Due to their small scale, weak edges, low contrast, and elongated morphology, micro-cracks are easily affected by metallic reflections, uneven illumination, and complex background textures in borescope images, resulting in high missed-detection rates for conventional detection methods. To address these challenges, this study proposes an improved YOLO11-based framework for aero-engine blade micro-crack detection. The proposed method introduces P1/P2 shallow high-resolution detection branches to enhance the perception of fine crack edges and textures, incorporates Focal Loss to alleviate foreground–background imbalance, applies object-level Tversky Loss to strengthen false-negative constraints, and adopts a hard mining strategy to improve learning for difficult crack samples. Experiments conducted on a real aero-engine borescope image dataset demonstrate that the proposed model achieves a Precision of 0.9981, Recall of 0.9606, F1-score of 0.9790, mAP50 of 0.9781, and mAP50-95 of 0.6938 on an independent test set. Compared with the YOLO11 baseline, the proposed method significantly improves crack detection accuracy, localization quality, and robustness in complex borescope inspection scenarios.