VT 2

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.
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.
Flaw Detection
Normal inspection practices for
highway bridges rely almost
entirely on visual inspection to
evaluate the condition of the
bridges.
Flaw Detection
Over 80 percent of all aircraft
inspections are performed visually.
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.
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
Visual inspection is commonly used to determine weld size and tolerances
according to standards and engineering specifications.
Throat measurement Leg size determination Convexity measurement with

using a Palmgren gage. with fillet gage. VWAC gage.
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.
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.
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 measure.
Measurements are then taken at various locations
and compared to code requirements. In this image a
fabricated girder is
being inspected for
distortion, sweep and
web flatness.

VT 2

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Basic Principles – Perspective

The eye/brain need visual clues

Is the book facing towards

• In this example, visual

Transverse weld crack

Slag rolled into toe of weld

Throat measurement Leg size determination Convexity measurement with

The finished depth of a Small hole gage used in

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