VISUAL TEST

Visual inspection is probably the most widely used among all the non-destructive tests.
It is simple, easy to apply, quickly carried out, and usually low in cost. Even though a
component is to be inspected using other NDT methods, a good visual inspection should
be carried out first.

BASIC PRINCIPLE
The basic procedure in visual NDT involves illumination of the test specimen with light,
usually in the visible region. The specimen is then examined with eye or by light sensitive
devices such as photocells.
THE EYE

• The most valuable NDT tool is the human eye.

• The eye has excellent visual perception.
• The sensitivity of the human eye varies for light with different wavelengths.
• The eye is most sensitive to yellow-green light, which has a wavelength of 5560Ao.
• The human eye will give satisfactory vision over a wide range of conditions.
• The eye can not be a good judge for distinguishing the differences in brightness or
intensity, except under the most restricted conditions.
• For visual inspection, adequate lighting i.e. about 800-1000 lux is of prime importance
• To avoid errors due to decrease in visual reliability and discrimination, it is not permitted
to work more than 2 hours.
Defects Which can be Detected by Unaided Visual Inspection

Visual inspection of a component by an experienced inspector can reveal the following

information:
(a) the general condition of the component,
(b) the presence or absence of oxide film or corrosive product on the surface,
(c) the presence or absence of cracks, orientation of cracks, and position of cracks relative to the
various zones in the case of welds,
(d) the surface porosity, unfilled craters, the contour of the weld beads, and the probable
orientation of the interface between the fused weld bead and the adjoining parent metal,
(e) potential sources of mechanical weakness such as sharp notches or misalignment etc. and
(f) the results of visual examination may be of great assistance to other tests.
OPTICAL AIDS USED FOR VISUAL INSPECTION

The use of optical instruments in visual inspection is beneficial and is recommended to

(a) magnify defects, that cannot be detected by the unaided eye and
(b) permit visual checks of 'areas not accessible to the unaided eye.
Magnifying devices and lighting aids should be used wherever appropriate

Microscope
An optical microscope is a combination of lenses used to magnify the image of a small object. The
object is placed close to the lens to obtain as high a magnification as possible. The distance from the
lens to the object is adjusted until the object is at the depth of field of the lens and is in focus.
The simplest form of a microscope is a single converging lens, often referred to as a simple
magnifier. Magnification (M) of a single lens is determined by the equation
M = 10/f
In this equation, f is the focal length of the lens and 10 is a constant that represents the average minimum distance at
which objects can be distinctly seen by the unaided eye.

The field of view is the area seen through the magnifier.

Depth of field is the term used to indicate the distance a magnifier can be moved towards or away
from a subject with the subject remaining in good focus

Minute defects and details of fine structures on a surface can be detected more easily with the aid
of a microscope. Optical microscopes are used to evaluate with respect to the shape and
orientation of cracks.
Borescope

o A Borescope is an instrument designed to enable an observer to inspect

the inside of a narrow tube, bore, or chamber.
o Borescope consists of precision built-in illumination system having a
complex arrangement of prisms and plain lenses through which light is
passed to the observer with maximum efficiency.
o Borescopes are available in numerous models from 2.5 to mm in
diameter.
o Optical systems are generally designed to provide direct, right-angle,
retrospective and oblique vision.

Borescopes are mostly used in nondestructive testing techniques for recognizing defects or
imperfections. Borescopes are commonly used in the visual inspection of aircraft engines,
aero-derivative industrial gas turbines, steam turbines, diesel engines, and automotive and
truck engines.
Endoscope

➢ The endoscope is much like a borescope except that it has a superior optical system and a high-
intensity light source. Various viewing angles, as discussed in the case of Borescope, can be
used.
➢ A unique feature of the endoscope is that objects are constantly in focus from about 4 mm to
infinity.
➢ The ‘no- focussing’ feature of the endoscope makes it much easier to use than a borescope.
➢ Endoscopes are available in diameters down to 1.7mm and in lengths from 100 to 1500 mm.
Flexible Fibre-Optic Borescope (Flexiscope)

▪ Flexible fibre-optic borescopes permit manipulation of the instrument around corners and through
passages with several directional changes.
▪ These devices are designed to provide sharp and, clear images of parts and interior surfaces that
are normally impossible to inspect.
▪ Remote end-tip deflection allows the viewer to thread the fiberoscope through complex and series
of bends.
▪ Most of the devices have a wide-angle objective lens that provides a 100o field of view and tip
deflection of ± 90°.
▪ They all have a fibre-optic image bundle and are equipped with a focus control lo bring the subject
into sharp focus over wide range of viewing distances.
▪ The working lengths are normally from 60 to 365 cm, with diameters from 3 to12 mm.
Telescope

• Telescope is used to obtain magnified images of objects at considerable -distance from the
• eye.
• It is particularly useful for providing visual examination of the surface which is otherwise
inaccessible.
• It consists, essentially, of two lenses (or lens systems) called the objective and eye piece.
• The telescope can be used in conjunction with a periscope for viewing a concealed surface.
• Closed Circuit Television (CCTV) can also be used for this purpose.
Holography

Holography is the name given to the method of obtaining an accurate three-dimensional image of a
given object. The process is carried out in two stages. First, a permanent record in the form of a two
dimensional interference pattern is obtained on a photographic plate by means of a laser beam. The
three dimensional image is then obtained from the two dimensional record, again using a laser. In
this way, a picture having a high definition and free from aberrations can be obtained without the use
of a camera.

Holography is used for the NDT of surfaces of highly complicated and precision components
without the disadvantages of having to use a high-power microscope. In a simple operation, a
hologram can provide a record of the image of an entire surface which can be readily compared with
that of a standard defect free surface.
APPLICATIONS

(a) Inspection of plant systems/component for any leakage, abnormal operation etc.
(b) Misalignment of parts in the equipments.
(c) Corrosion, erosion, cracks, fracture etc.
(d ) Defects in the new/repaired weldments such as gross surface cracks, lack of penetration,
tear cracks, excess reinforcements, porosities, mismatch etc.
(e) Minute discontinuities with the help of optical aids in pumps, compressors, turbogenerator
parts, instruments etc.