Visual Inspection

Outline
• Introduction
• Basic principles
• Manual Vision Inspection
– Human Vision
– Common Inspection applications
– Equipment
• Automated or Machine Vision Inspection
– Machine Vision
– Common Inspection Applications
– Equipment
• Advantages and Limitations
• Glossary of terms
 Introduction
• Visual inspection is commonly defined as “the examination of a
material, component, or product for conditions of
nonconformance using light and the eyes, alone or in
conjunction with various aids.
• Visual inspection often also involves, shaking, listening, feeling,
and sometimes even smelling the component being inspected.
• Visual inspection consists of at least two major processes.
– The first is a search process.
– The second is a process of combining relevant knowledge, sensory
input, and pertinent logical processes to provide an identification
that some anomaly or pattern represents a flaw that poses a risk to
the performance of the part.
• Visual inspection is commonly employed to support other NDT
methods.
• Digital detectors and computer technology have made it
possible to automate some visual inspections. This is known
as “machine vision inspection.”
 Introduction
• Visual inspection is the most basic and most
commonly employed NDT method.
• It is applicable to a wide variety of material types and
product forms.
• Several characteristics about the part being examined
may be determined, which include dimensional
conformance, the presence of discontinuities, general
fit and wear, and simple cosmetic compliance.
• It can be performed by direct or indirect methods
during various stages of manufacturing or after the
component has been placed in-service.
 Introduction
• The quality of an inspection are affected primarily by
four factors.
– The quality of the detector (eye or camera).
– The lighting conditions.
– The capability to process the visual data.
– The level of training and attention to detail.
 Introduction –
Manual Versus Automated Inspection
• The majority of visual
inspections are completed
by an inspector, but
machine vision is becoming
more common.
• The primary advantage of an
inspector is their ability to quickly adapt to a variety of
lighting and other non-typical conditions, and their
ability to use other senses.
• The primary advantage of a machine vision inspection
system is their ability to make very consistent and rapid
inspections of specific details of a component.
• Machine vision is primarily used in production
applications where a large number of components
require inspection and the inspection conditions can be
closely controlled.
Basic Principles –
The Human Eye
• Light enters the eye through
the pupil and an image is
projected on the retina.
• Muscles move the eyeball in
the orbits and allow you to
focus the image on the central
retina or fovea.
 Basic Principles –
The Human Eye

The retina is a mosaic of two basic types of photoreceptors, rods and cones.
• Rods are sensitive to blue-green light and are used for vision under dark or dim conditions.
• Cones operate only in relatively bright light, but they provide us with our sharpest images
and enable us to see colors. There are three types of cones
– L-cones are red absorbing cones or those that absorb best at the relatively long wavelengths
peaking at 565 nm
– M-cones are green absorbing cones with a peak absorption at 535 nm
– S-cones are blue absorbing cones with a peak absorption at 440 nm.
 Basic Principles – Visual Acuity
• Cones provide us with our sharpest
images because most of the 3 million
cones in each retina are confined to a
small region just opposite the lens
called the fovea. The maximum
concentration is about 180,000 cones
per square mm.
• Our sharpest and most colorful images
are produced in the fovea.
• Outside of this region our vision is
relatively poor but, since we can quickly
redirect our eyes we tend not to be
aware of our poor peripheral vision.
 Basic Principles – Visual Acuity

There is a b n c
’ 180,000
limit to what
X/2
2 ’ 1 mm
X  Cones
the unaided b’

1 mm

eye can see. ~425 by 425 cones

d d’

• Normal visual acuity or 20/20 vision is defined as the ability to resolve a

spatial pattern separated by a visual angle of one minute or 1/60 of a
degree of arc.
• One degree of a scene is projected on about 290 micrometers of the retina.
• In 290 micrometers there are 123 cones and in 1/60 of a degree there 2
cones which is the number required to resolve an object.
• The size of an object that can be seen at a given distance can be calculated
using the following formula: X = (d tan /2)2
When visually inspecting an object for a defect, a comfortable viewing distance “d” might
be around 12 inches. At 12 inches, the normal visual acuity of the human eye is 0.0035
inch. (It must be noted that this value is for the situation where there is good lighting and high contrast
between the objects being viewed.)
 Basic Principles –
Contrast Sensitivity
• Contrast sensitivity is a measure of how faded or
washed out an object can be before it becomes
indistinguishable from a uniform field
• It has been experimentally determined that the
minimum discernible difference in gray scale level
that the eye can detect is about 2% of full brightness
• Contrast sensitivity varies with
– the size or spatial frequency
of a feature
– The lighting conditions
– Whether the object is lighter
or darker than the background

The graph to the right plots the

visibility of a spot as a function of the
above variables
 Basic Principles –
Contrast Sensitivity
It should be noted, however, that
larger objects are not always
easier to see than smaller objects
as contrast is reduced.

In this image:
– The luminance of pixels is varied
sinusoidally in the horizontal
direction. The spatial frequency
increases exponentially from
left to right.
– The contrast also varies
logarithmically from 100% at the
bottom to about 0.5% at the top.
– The luminance of peaks and Campbell, F. W. and Robson, J. G. (1968) Application of Fourier analysis to
troughs remains constant along the visibility of gratings. Journal of Physiology (London) Image Courtesy
of Izumi Ohzawa, Ph.D. University of California School of Optometry
a given horizontal path through the image.

If object visibility was dictated solely by image contrast, the alternating

bright and dark bars should appear to have equal height everywhere in the
image. However, the bars seem to be taller in the middle of the image.
 Basic Principles – Light Levels
• Under normal lighting conditions the
cones are operating and the eye has
good visual acuity and is most
sensitive to greenish yellow color,
which has a wavelength around 555
nanometers (photopic curve).
• When the light levels drop to near total
darkness, the response of the eye
changes significantly as shown by the
scotopic response curve on the left.
• At this level of light, the rods are most
active and the human eye is more
sensitive to any amount of light that is
present, but is less sensitive to the
range of color.
• At this very low light level, sensitivity
to blue, violet, and ultraviolet is
increased, but sensitivity to yellow and
red is reduced.
 Basic Principles –
Light Intensity Measurement
• Effective visual inspection requires adequate
lighting.
• The type of inspection will dictate the lighting
requirements. Inspection of components with
fine detail and low contrast will require greater
illumination than components with large details
and high contrast.
• Light intensity may be measured with a suitable
light meter. The unit of measure for white light is
foot-candles (fc).
– A foot-candle is equal to the amount of direct light
thrown by one standard candle at a distance of 1
foot.
• Inspection of components with fine detail and
low contrast may require 100 foot-candles or
more.
• Specification requirements for lighting should be
reviewed prior to performing an inspection.
 Basic Principles –
Light Directionality
• The directionality of the
light is a very important
consideration.
• For some applications,
flat, even lighting
works well.
• For other applications,
directional lighting is
better because it
produces shadows that
are larger than the
actual flaw and easier
to detect.
 Basic Principles – Perspective
The eye/brain need visual clues
to determine perspective.

Is the book facing towards

or away from you?
 Basic Principles –
Optical Illusions
Sometime the eye/mind has trouble correctly processing
visual information.

Are the horizontal lines parallel or How many black dots do you see?
do they slope?
 Basic Principles – Vision
• When evaluations are made by an
inspector, eye examinations must be
done at regular intervals to assure
accuracy and sensitivity. These
examinations may consist
of the following:
• Near Vision (Jaeger)
• Far Vision (Snellen)
• Color Differentiation
• When using machine vision, different
but similar performance checks must
be performed.
 Basic Principles
• For best results the inspector or
machine vision operator must have:
– A basic knowledge of material processing,
forming, machining and joining processes.
– A general understanding of design features,
application and service requirements.
– Specific instructions on what to look for and
specific accept/reject criteria.
 Inspection Applications
Applications for visual inspection and many and range
from looking a product over for obvious defect to
performing detailed inspections. Some of the common
applications include:
• Detection of surface anomalies such as scratches,
excess surface roughness, and areas void of paint
or plating.
• Crack, porosity, corrosion or other flaw detection.
• Dimensional conformance.
• Precision measurements.
• Foreign object detection.
• Component location.
 Inspection Applications –
Flaw Detection
• Visual inspection of
manufactured materials
and components is a
cost effective means of
identifying flaws.
• Visual inspection of a
casting reveals a crack
between a threaded
opening and a pressed
fit.
• The aluminum sand
casting has hot tears
and shrinkage at the
transition zones.
 Inspection Applications –
Flaw Detection
In-service inspections of
existing components and
structures is commonly
accomplished visually.
• In this example, visual
inspection of a fire escape
reveals a failure in a
handrail tube.
• The failure is in the tube
seam and is likely the
result of ice expansion.
 Inspection Applications –
Flaw Detection
Normal inspection practices
for highway bridges rely
almost entirely on visual
inspection to evaluate the
condition of the bridges.
 Inspection Applications –
Flaw Detection
Over 80 percent of all aircraft
inspections are performed
visually.
 Inspection Applications –
Flaw Detection
• Weld quality requirements
are commonly determined
through visual inspection.
• Many standards have
established acceptance
criteria for welds.

Transverse weld crack

Slag rolled into toe of weld

 Dimensional Conformance
• Visual inspection is commonly employed for
general dimensional conformance, assembly
fit, and alignment between components.
• Common applications include determining:
– Weld size and tolerance.
– Component dimensions.
– Material alignment and allowable distortion.
 Dimensional Conformance
Welds are commonly inspected for dimensional tolerance.
• There are several types of gages used to inspect welding fit up
and finished weldments.
• These gages are intended for general inspection where close
tolerances are not required.
• The gage used is determined by the application.

Palmgren gage
Fillet gage set

VWAC gage

Cambridge gage
 Dimensional Conformance
Visual inspection is commonly used to determine weld size and
tolerances according to standards and engineering specifications.

Throat measurement Leg size determination Convexity measurement

using a Palmgren gage. with fillet gage. with VWAC gage.
 Dimensional Conformance
Undercut in a weld is readily seen visually. In many cases its
depth must be measured to determine if it exceeds code
requirements.

Measurement of undercut
depth with VWAC gage.
 Dimensional Conformance
Component finish dimensions are checked with the use of
measurement devices, such as transferring gages and
precision measurement gages.

The finished depth of a Small hole gage used in

machined mold is determined determining hole diameter.
with a depth micrometer.
 Dimensional Conformance
Alignment/Distortion
• Visual inspection frequently involves
checking materials and components for fit
and alignment.
• Many standards establish allowable
tolerances for fit and distortion.
• Structural fabrication requires dimensional
inspection of finished components prior to
shipment to the field site.
• Basic tools are used for the inspection. An
inspector will set up string lines at known
distances and plum them using a tape In this image a
measure. Measurements are then taken at fabricated girder is
various locations and compared to code being inspected for
requirements.
distortion, sweep
and web flatness.
 Equipment
• Visual inspection equipment includes a variety of
different tools. These may range from basic rulers,
tape measures and spring type calipers to rigid or
flexible borescopes and remote crawlers with
cameras.
• Many tools have been designed for specific
applications such as the various weld gauges.
• Some of the specialized tools such as crawlers have
been designed to satisfy the inspection needs in
applications where conventional techniques are not
feasible.
Equipment – Basic Measurements
• One of the most common tools
used in visual inspection is the
rule or scale.
• Used to measure linear
dimensions, when properly used
will measure within 0.015” or
1/64” and smaller.
• Rules are made in a variety
lengths, widths, and thicknesses.
• They are graduated in common
fractions, decimal units, and
metric units, or combinations of
both.
• The specific type of rule is
typically chosen relative to the
application.
 Equipment –
Precision Measurements
• Sliding calipers are a
precision refinement of the
common rule, which results
in greater accuracy of
measurements.
• They may incorporate either
a dial indicator or digital
readout.
• Sliding-type calipers are
commonly used to check
dimensional tolerances of
machined components, wear
on components, and fit
between components.
 Equipment –
Precision Measurements
• Micrometers are precise
measurement instruments
used to make accurate direct
readings in contact
measurements.
• Micrometers are designed for
inside, outside, and depth
measurements, and are
available in a wide variety of
shapes and sizes.
• Micrometers may be either
thousandth inch (.001”) or ten
thousandth inch (.0001”)
measurement capable.
 Equipment –
Precision Measurements
• Micrometers operate on the
principle that a precision
made screw with a pitch of
forty threads per inch will
advance one fortieth of an
inch (.025”) with each
complete turn.
• On a one inch micrometer,
the sleeve is marked
longitudinally with forty
lines to the inch which
corresponds to the number
of threads on the spindle.
 Equipment –
Precision Measurements
• The reading line on the
sleeve is divided into forty
equal parts by vertical lines,
each designates 1/40th”
or .025” and every fourth
line denotes hundreds of
thousandths and is
numbered 1 – 0.
• The beveled edge of the
thimble is divided into
twenty five equal parts with
each representing .001”,
with every line numbered
from 0 -24.
 Equipment –
Precision Measurements
Example:
– One major division on the sleeve is
visible, representing one tenth of an inch.
– Two minor divisions are visible, which
each represent an additional 25
thousandths.
– Line 15 on the thimble coincides with the
reading line on the sleeve indicating that
fifteen one thousandths of an inch
should be added to the measurement.
– By adding all three values, the
micrometer reading is obtained. 0.100”
(2 X 0.025) 0.050”
(15 X .001) 0.015”
0.165”
 Equipment –
Precision Measurements
Reading the ten thousandths micrometer.
• The ten thousandths micrometer incorporates a vernier scale.
• The vernier consists of ten divisions the sleeve, which occupies the same space as
nine divisions on the beveled edge of the thimble.
• The difference between one of the ten spaces on the sleeve and one of the nine
spaces on the thimble is 1/10th of a division or 0.0001”.

Example:
− The second major divisions (line 2) on the
sleeve is visible (2 x 0.100” = 0.200”)
− Three minor divisions after line 2 are visible
(3 X 0.025” = 0.075”)
− The beveled edge of the thimble is between
0 and 1 (0 x 0.001 = 0)
0.200”
− The vernier scale has the sixth line on the
0.075”
sleeve perfectly lined up with one of the
marks on the thimble ( 6 x 0.0001 = 0.0006”) 0.000”
0.0006”
− The micrometer reading is: 0.2756”
0.2756”
Equipment – Transferring Gauges
• Transfer instruments are
used to take measurements
which are transferred to
direct measurement devices.
• They consist of calipers,
dividers, telescoping gages
and small hole gages.
Equipment – Transferring Gauges
• Spring type calipers are available
for contact measurements of inside
and outside dimensions.
• They are useful for measuring
distances between and over
surfaces.
• They are commonly used to
transfer dimensions or sizes
between the work piece and
standard measuring devices, such
as graduated rules.
• The size of a linear or rounded
indication of a discontinuity may be
measured with dividers.
Equipment – Transferring Gauges
• Small hole gages are a type of transfer instrument used to
measure small holes or slots.
• They are generally supplied in sets with a range of 1/8” - 1/2”.
• The actual measurement is determined by transferring a
properly adjusted gage to a micrometer.
Equipment – Transferring Gauges
• Telescoping gages make
inside measurements such as
hole diameter and slot width.
• They are designed to be
measured by a micrometer
after being set to the hole or
slot size.
• To make accurate
measurements it is important
to make sure the telescoping
gage is aligned properly in
the measuring faces of the
micrometer.
 Equipment – Screw Pitch Gage
• The screw pitch gage is a
basic visual aid for checking
the number of threads per
inch and rough inaccuracies
of threads.
• The gage consists of a steel
case with a number of folding
leaves at each end.
• Each leaf is number and
contains teeth corresponding
to a specific thread pitch.
 Direct and Remote
Visual Inspection
• Many codes refer to direct visual examination as a
visual inspection which requires that access to the
area is sufficient to place the eye within 24 inches of
the surface to be examined and at an angle of not
less than 30º to that surface.
• If these requirements cannot be met, then remote
visual inspection may be used.
• Remote visual inspection may be accomplished with
the use of a number of optical aids such as, mirrors,
magnifiers, and rigid or flexible borescopes.
 Optical Aids
• Mirrors are valuable aids in visual
inspection, they allow the inspection
of threaded and bored holes, inside
surfaces of pipes and fittings, as
well as many others.
• Magnifiers assist the visual
inspector by enlarging the size of
the object being examined.
• Comparators are a magnifier with a
measuring capability. The
comparator has interchangeable
reticles which provide
measurements for threads, angles,
linear measurement, diameters and
radii.
 Optical Aids
• Borescopes are visual aids used for the inspection of internal
surface areas.
• They are designed for remote viewing in difficult to reach
areas such as jet engines, cylinders, tanks, and various
enclosed chambers.
• Borescopes are available in many different diameters and
lengths, and are classified as rigid or flexible.
Visual Inspection With A Borescope

Clean Surface Corrosion Damage

 Optical Aids
• Advances in technology has allowed video equipment
to be adapted to portable and robotic devices.
• Portable video probes allow inspectors to remotely
perform examinations in closed chambers which are
inaccessible by convention inspection means.
• Robotics have been developed whereby cameras can
be affixed to crawlers and submersibles.
– Retrieval tools can be affixed to robotics to remove
foreign objects.
• Conventional recording techniques may
be employed for image capture and
storage with many of the remote video
inspection methods.
Machine Vision Inspection
Machine Vision – Basic Principles
• Machine vision technology uses an imaging system
and a computer to analyze an image and to make
decisions based on that analysis.
• In inspection applications, the machine vision optics
and imaging system enable the processor to "see"
objects precisely and thus make decisions about which
component meet a specific inspection criteria.
• Machine vision can eliminate human factor error that
might result from doing difficult, tedious, or boring
tasks. It also allows process equipment to be utilized
24 hours a day.
Machine Vision – Basic Principles
The following process steps are common to all machine
vision applications:
• Image acquisition: An optical system gathers an image, which is then
converted to a digital format and stored into computer memory.
• Image processing: A computer processor uses various algorithms to
enhance elements of the image that are of specific importance to the
process.
• Feature extraction: The processor identifies and quantifies critical
features in the image (e.g., the position of holes on a printed circuit
board, the number of pins in a connector, the orientation of a
component on a conveyor) and sends the data to a control program.
• Decision and control: The processor's control program makes
decisions based upon the data. Are the holes within specification? Is a
pin missing?
 Machine Vision - Applications
As mentioned previously, machine vision is primarily used in
production applications where a large number of components
require inspection and the inspection conditions can be closely
controlled. Uses include:
• Assembly verification (caps, fasteners,
electronic board components, etc.)
• Surface inspection (dents, scratches,
porosity.
and other undesirable features)
• Verification of colors, gradients, patterns

in fabrics and labels. Assembly Verification

• Confirmation of proper labeling for
medications, foods and other products.
• Inspection of coating coverage.
• Feature measurements.
Spark Gap Measurement
 Machine Vision - Equipment
Key System Elements
• A variety of components are
included in a machine vision
system, which depend on the
environment, the application,
and the budget. However, the
following components are
common to all vision systems :
– Front-end optics: this includes the lighting, the lens, and the
camera.
– Frame grabber: this is a computer processor board that accepts the
video input from the camera, digitizes it, and stores it for analysis.
– Processor: A computer processor is required to control the vision
application.
– Control Software: Computer software is used for controlling and
executing vision tasks.
Advantages of Visual Inspection
• Readily used on almost all materials.
• Simple to perform.
• Low in cost, (application dependent).
• Relatively quick.
• Results may be permanently recorded.
• Can be automated.
 Limitations of Visual Inspection
• Direct inspections are limited to surfaces only.
• Indirect inspections require greater inspector
knowledge and training.
• Inspector dependent, knowledge of materials and
processing, eye sight.
• Standards (workmanship) may be difficult to obtain.
 Glossary of Terms

• Borescope: A visual inspection aid used for the inspection of

internal surfaces. Borescopes are rigid and flexible.

• Corrosion: The deterioration of a metal by chemical or electro-

chemical reaction with its environment.

• Defect: A discontinuity which interferes with the usefulness of a

part. A fault in any material or part which is detrimental to its
serviceability.
 Glossary of Terms, Cont.

• Direct Visual Inspection: Visual inspection conducted where the eye

can be place within 24” of the area to be inspected at an angle of
not less than 30˚.

• Discontinuity: An interruption in the normal physical structure or

configuration of a part.

• Foot Candle: The amount of direct light thrown by one standard

candle on a surface one foot away.
 Glossary of Terms, Cont.

• Inherent Discontinuity: Discontinuities which are ordinarily normal to

the material at the time it originally solidifies from the molten state.
They consist of porosity, inclusions, and pipe.

• Magnifier: An optical glass which enlarges the real size of an object

being inspected

• Micrometer: A precise measuring instrument used to take accurate

readings in contact measurement.
 Glossary of Terms, Cont.

• Pocket Comparator: A magnifier with measuring capability through

a system of interchangeable reticles.

• Power of Magnification: The amount that the real size of an object

is enlarged. The power if designated by “X”.

• Remote Visual Inspection: Inspection conducted where the eye

cannot be placed within 24” of the area to be inspected, or at an
angle less than 30˚.
 Glossary of Terms, Cont.

• Reticle: A series of lines, dots, cross hairs, or wires in the focus of

the eyepiece of and optical instrument.

• Rule or Scale: A measuring device used to make linear

measurements.

• Screw Pitch Gages: A visual aid used to check the number of

threads per inch and rough inaccuracies in threads.
 Glossary of Terms, Cont.

• Secondary Processing: Metal removal processes, heat treatment

and plating processes used to produce and article of the desired
shape and finish from the formed material.

• Service Discontinuity: Discontinuities induced in components after

they have been placed in service.

• Transfer Instruments: A group of instruments used to take

measurements which are transferred to precise direct measuring
devices. They consist of calipers, dividers, telescoping gages, and
small hole gages.
 Glossary of Terms, Cont.

• Vernier Scale: A device for indicating a fraction of a whole division

of a scale reading

• Visual Scale: The ability to see. The keenness of perception.

• Wear: Wear is deterioration due to use. Wear will cause a

reduction in cross section and strength.

• Weld Inspection Gages: A group of measuring devices used to

inspect welding fit up and finished weldments.