Physical-Surface Localization of Aircraft Fuselage Corrosion Using Camera-Calibrated Vision Measurement and Cross-Validated Detector-Center Correction

Aircraft fuselage corrosion inspection requires both image-domain recognition and metric physical-surface localization for maintenance execution. This study develops a camera-calibrated vision measurement framework that combines PWDE-YOLOv8n-based corrosion perception, original-image coordinate restoration, lens-distortion compensation, ray-based surface mapping, and detector-center bias correction. The perception dataset comprised 2143 images and 5941 corrosion annotations and was partitioned at the physical-specimen, acquisition-session, or source-group level into 1500 training images, 429 validation images, and 214 independent detector-test images. Detailed physical localization was evaluated on a six-image metrology cohort acquired in six sessions, containing 21 corrosion boxes and 84 axial coordinates. A six-fold leave-one-image-out procedure was adopted; in each fold, the center-shift parameters were estimated from the other five images and applied unchanged to the held-out image. The proposed method achieved a mean absolute axial error of 0.641 mm (95% image-cluster bootstrap confidence interval: 0.571–0.708 mm), an RMSE of 0.809 mm, a maximum error of 3.262 mm, and a projected physical-plane bounding-box IoU of 87.12%. The expanded uncertainty of the manually established reference coordinates was 0.374 mm at k = 2, and Monte Carlo propagation produced a mean absolute error of 0.656 mm with a 95% interval of 0.618–0.693 mm. The proposed method reduced the MAE by 97.91% relative to local pixel-to-millimeter scaling and by 70.58% relative to conventional calibrated camera mapping, while producing accuracy comparable to planar homography mapping. Within ρ ≥ 1500 mm, W ≤ 150 mm, and θ ≤ 20°, the estimated curvature-induced additional axial error did not exceed 0.683 mm. A separate ten-image deployment evaluation produced a mean axial error of 2.448 mm and an average processing time of 53.35 ms/image.