VISUAL INSPECTION

ASME – SECTION 5 – ARTICLE 9

PURPOSE :-
Observation or inspection of test surface
by using either or all of raw human
senses such as vision, hearing, touch and
smell and/or any non-specialized
inspection equipment.
 Visual testing is used in all industries and at
every step of a component’s lifecycle. VT NDT
can easily find and evaluate the following
DISCONTINUITY TYPES: -
Cracks
Holes
Corrosion
Blisters
Impact damages
Most other discontinuities that are surface
breaking or result in a deformation at the surface
The eye :-
➢Human eye is the most valuable NDT tool.
➢Human eye having an excellent visual
perception.
➢Sensitivity of human eye will be change
based on the light source.
➢Yellow and green color light with wavelength
of 5560°A is the most suitable light or human
eye at normal condition.
Advantages of visual inspection:-

➢Low cost inspection

➢Portable equipment

➢Quick method

➢Less maintenance

➢We can get spot results

Disadvantages of visual inspection:-

➢Applicable for only detection of surface

defects

➢Highly skilled and experienced person

required

➢Test surface should be cleaned during

inspection
Annual eye certification required for

Near vision or myopic eye with Jaeger chart

Far vision or hyperopic eye with snellen chart

Color vision with ishihara chart

 Jaeger chart
Near vision acuity is addressed in NDT
certification standards and one of the most
common means to measure near vision acuity
for NDT personnel in the U.S. is to have them
read text from a standardized reading card
called the Jaeger chart.
Jaeger chart
 Snellen chart

The so-called “Snellen chart” is an eye chart

that is used to measure visual acuity, or how

well somebody sees. The Snellen chart is the

most prevalent eye chart

Snellen chart
 Ishihara test
The Ishihara test is a color perception test for red-
green color deficiencies. The test consists of a
number of colored plates, called Ishihara plates,
each of which contains a circle of dots appearing
randomized in color and size. Within the pattern are
dots which form a number or shape clearly visible
to those with normal color vision, and invisible, or
difficult to see, to those with a red-green color
Ishihara chart
Types of visual inspections:-

1) Aided visual inspection

2) Unaided visual inspection

Unaided visual inspection:-

Inspection of test surface with out use of any

optical, mechanical or electrical tools
Aided visual Inspection

Inspection of test surface by using any optical

,mechanical or electrical tools

Tools of aided visual inspection:-

Optical aids

Microscopes, Borescopes,Fiberscopes,Videocamera.
Microscope
 Microscope
A microscope is a laboratory instrument used
to examine objects that are too small to be
seen by the naked eye. microscopy is
the science of investigating small objects and
structures using a
microscope. microscopic means being invisible
to the eye unless aided by a microscope.
Borescope
 Borescope
A borescope is an optical instrument designed to
assist visual inspection of narrow, difficult-to-
reach cavities, consisting of a rigid or flexible tube with
an eyepiece or display on one end, an objective
lens or camera on the other, linked together by an optical
or electrical system in between. The optical system in
some instances is accompanied by illumination to
enhance brightness and contrast. An internal image of
Fiberscope
 Fiberscope

A fiberscope is a flexible optical fiber bundle

with an eyepiece on one end and a lens on the

other that is used to examine and inspect

small, difficult-to-reach places such as the

insides of machines, locks, and the human

Video camera
 Video camera

A video camera is an optical instrument used

to capture an image. At their most basic,
cameras are sealed box with a small hole that
allows light in to capture an image on a light-
sensitive surface. Cameras have various
mechanisms to control how the light falls onto
the light-sensitive surface
Mechanical or electrical aids

Screw gauge

Depth gauge

Calipers

Thread pitch gauge

Bridge cam gauge

Hi-lo gauge

Feeler gauge
Screw gauge
 Screw gauge
• A micrometer, sometimes known as a micrometer
screw gauge, is a device incorporating a calibrated
screw widely used for accurate measurement of
components in mechanical engineering
and machining as well as most mechanical trades,
along with other metrological instruments such
as dial, vernier, and digital callipers . Micrometers
Depth gauge
 Depth gauge

A depth gauge is an instrument for measuring

depth below a reference surface. They include
depth gauges for underwater diving and
similar applications, and engineering
instruments used to measure the depth of
holes and indentations from a reference
surface.
Vernier Caliperse
 Vernier calipers
A vernier calipers is a device used to
measure the dimensions of an object includes
fallowing..
Thickness
Depth
Pipes outer diameter
Pipes inner diameter
Thread pitch gauge
 Thread pitch gauge
• A thread gauge, also known as a screw
gauge or pitch gauge is used to measure the pitch of
a screw thread.

• Thread pitch gauges are used as a reference tool in

determining the pitch of a thread that is on a screw
or in a tapped hole. This tool is not used as a
precision measuring instrument, rather it allows the
Bridge cam gauge
 Bridge cam gauge
The Bridge Cam Gauge, commonly known as the

Cambridge gauge, is an accurate, sturdy gauge

for both shop and field applications. It can

measure fillet weld leg length and throat

thickness, height of weld reinforcement, depth of

 Applications
➢ Applicable for measuring angle of preparation.

➢ Applicable for measuring out side miss

alignment.

➢ Applicable for measuring weld reinforcement

height.

➢ Applicable for measuring depth of pits and

undercuts.
Hi – Lo gauge
 Hi – Lo gauge

• Hi – Lo gauge Measures internal alignment of

pipe after fit-up/alignment, cuts radiographic
rejects

• Measures internal misalignment of pipe

before and after tracking

• Measurement Scale: Inches on one side and

Metric on the opposite side
 Applications
➢Applicable for measuring internal miss
alignment.

➢Applicable for measuring thickness of pipe

after fit up.

➢Applicable for measuring fillet weld leg length.

➢Applicable for measuring weld cap height.

➢ Applicable for verification of 37.5° bevel angle

after fit up.
Feeler gauge
 Feeler gauge
• A feeler gauge is a tool used to measure gap
widths. Feeler gauges are mostly used
in engineering to measure the clearance
between two parts.
Viewing distance and angle
➢ Viewing distance will be depends upon the
viewing angle

➢Acceptable viewing distance will be 6 to 12inch for

30 to 50 degree.

➢Viewing distance should be more than 24inch for

90degrees angle to avoid illusion effect.

➢Viewing distance should not be less than 6inch

and angle should not be less than 30degree.
Light requirement
➢Lighting is the main requirement for visual

inspection.

➢Recommended light intensity for visual

inspection will be 500 to 800lux.

➢Viewing angle should not be same as reflected

angle of light on test surface

 welding
Welding is a fabrication process that joins
materials, usually metals or thermoplastics ,
by using high heat to melt the parts together
and allowing them to cool, causing fusion .
Welding is distinct from lower temperature
metal-joining techniques such
as brazing and soldering , which do
not melt the base metal.
Most commonly used weldings
1) TIG welding
2) ARC welding
 TIG WELDING
Gas tungsten arc welding (GTAW), also known
as tungsten inert gas (TIG) welding, is an arc welding
process that uses a non-consumable tungsten
electrode to produce the weld. The weld area and
electrode are protected from oxidation or other
atmospheric contamination by an inert gas
shielding (argon or helium). A filler metal is normally
used, though some welds, known as autogenously
A constant-current welding power supply
produces electrical energy, which is conducted
across the arc through a column of highly
ionized gas and metal vapours known as
a plasma. GTAW is most commonly used to
weld thin sections of stainless steel and non-
ferrous metals such as aluminium
, magnesium, and copper alloys.
 ARC WELDING
Arc welding is a welding process that is used to
join metal to metal by using electricity to create
enough heat to melt metal, and the melted
metals, when cool, result in a binding of the
metals. It is a type of welding that uses a welding
power supply to create an electric arc between a
metal stick ("electrode") and the base material to
melt the metals at the point of contact. Arc
welders can use either direct(DC)
or alternating (AC) current, and consumable or
Weld measurements
Weld zones
Welding defects
 CLUSTER POROSITY

WHAT DOES IT LOOK LIKE?

• Cluster porosity will appear as rounded or slightly
• elongated dark spots that appear in clusters.
WHAT CAUSES IT?
• Clusters of trapped gas cause cluster porosity.
Porosity
• is the result of gas entrapment in the solidifying
metal. Porosity can take many shapes on a
radiograph but often appears as dark round or
irregular spots or specks appearing singularly, in
clusters or rows.
Blow hole
They are also called as endogenous
gas holes or blowholes.
These holes are caused due to excessive
gas content in the metal bath and rejection
of dissolved gases during solidification. ...
As casting solidifies the insoluble gas is
rejected and produces holes between
Types o porosities
 SCATTERED POROSITY

WHAT DOES IT LOOK LIKE?

• Scattered porosity appears as a dark and

sharply defined

• shadow with rounded contours.

WHAT CAUSES IT?

• Gas trapped in cavities produces scattered

 WELD SPATTER

WHAT DOES IT LOOK LIKE?

• Weld spatter appears as white spots near the

weld.
WHAT CAUSES THESE SPOTS?

• These spots are caused by the metal particles

• expelled during fusion welding that do not form a
• part of the weld.
cracks
 • CRACKS
WHAT DO THEY LOOK LIKE?

• Cracks in castings appear as dark linear indications.

• They may be either feathery or jagged.

WHAT CAUSES CRACKS?

• Cracks are caused when metal fractures during or

• after solidification.
 Longitudinal cracks
WHAT DO THEY LOOK LIKE?
• Longitudinal cracks are dark lines, either
continuous
• or intermittent, along the length of a weld.
WHAT CAUSES THEM?
• These cracks are discontinuities caused by
fractures
• along the length of a weld.
 TRANSVERSE CRACKS

WHAT DO THEY LOOK LIKE?

• A transverse crack is a fine dark line running
• across a weld image. These lines can be
straight
• or wandering.
WHAT CAUSES THEM?
• These cracks are caused by metal fractures
that
• occur across a weld.
Lack of fusions
Lack of side wall fusion
Lack of root fusion
 LACK OF FUSION
WHAT DOES IT LOOK LIKE?
• Lack of fusion appears as an elongated single, or
• several parallel, darker density lines. Unlike winding
• and elongated slag lines, lack of fusion lines are
• very straight and aligned lengthwise. Sometimes
• darker density spots are dispersed along the lack
• of fusion lines.
WHAT CAUSES IT?
• Lack of fusion is the result of elongated voids
• between the weld metal and base metal.
Burn through
 BURN THROUGH

WHAT DOES IT LOOK LIKE?

• A burn through is a localized darker density
area
• with fuzzy edges right in the center of the
weld
• image.
WHAT CAUSES IT?
• These are caused by a severe depression or a
• crater-type hole at the bottom of the weld.
Misalignment or mismatch
 MISMATCH

WHAT DOES IT LOOK LIKE?

• A mismatch is an abrupt change in film density

• across the entire width of the weld image.
WHAT CAUSES A MISMATCH?

• Mismatches occur when plates are not aligned

• properly before welding.
Lack of root penetration
 LACK OF PENETRATION

WHAT DOES IT LOOK LIKE?

• Lack of penetration will appear as dark lines, either

• continuous or intermittent, in the center of the

weld.
• WHAT CAUSES IT?

• There are two causes: either a lack of fusion in the

• root of the weld, or a gap left by the failure of the

EXTERNAL UNDERCUT
 EXTERNAL UNDERCUT
WHAT DOES IT LOOK LIKE?

• External undercut appears as an irregular dark

• density line that follows the edge of the weld

image.
WHAT CAUSES EXTERNAL UNDERCUTS?

• These appear when there’s a groove or

channel in
INTERNAL (ROOT) UNDERCUT
 INTERNAL (ROOT) UNDERCUT

WHAT DOES IT LOOK LIKE?

• Internal (root) undercut appears as an irregular dark

• density near the center of the weld image and along
• the edge of the root pass image.
WHAT CAUSES IT?

• An internal undercut is caused by a groove in the

• main object stretched along the edge, either at the
• bottom or at the inner surface of the weld.
EXCESS reinforcement
EXCESS ROOT PENETRATION
 EXCESS reinforcement AND
PENETRATION
WHAT DOES IT LOOK LIKE?

• Excess penetration appears as a lighter density

• area in the center of a weld image. This area can be
• extended along the weld or isolated in circular drops.
WHAT CAUSES IT?

• These indicators can appear when there is excess

• metal at the root of the weld.
UNDERFILL
 UNDERFILL

Underfill is a condition in which the weld face or

root surface extends below the adjacent surface
of the base metal.

Having too large of a root opening on

the weld joint can also result in burn through.
Increasing travel speed helps, too, especially
when welding on aluminum, which is prone to
heat build-up.
• Underfill or Inadequate weld reinforcement is
an area of a weld where the thickness of weld
metal deposited is less than the thickness of
the base material.

• The image density in the area of suspected

inadequacy will be more (darker) than the
image density of the surrounding base
material.
Root concavity
 Root concavity
Root concavity or suck back is condition
where the weld metal has contracted as
it cools and has been drawn up into the
root of the weld.

It causes due to sudden cooling of work

piece after welding’