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C
6H A P T E R

Indirect Visual Testing

Michael W. Allgaier, Mistras Group, Princeton Junction,


New Jersey
Thomas D. Britton, General Electric Sensing and
Inspection Technologies, Skaneateles, New York
(Part 3)
Trevor Liddell, General Electric Sensing and Inspection
Technologies, Lewistown, Pennsylvania (Part 3)

Portions of Parts 1 and 2 are reprinted with permission from Visual Examination Technologies (EPRI learning modules), © [ca. 1982 and] 1996,
the Electric Power Research Institute (EPRI), Charlotte, NC. ASNT has revised the text in 1993 and 2010, and deficiencies are not the
responsibility of the Electric Power Research Institute.
Portions of Part 3 are reprinted with permission from Nondestructive Testing: Remote Visual Inspection, training modules © [2005] General
Electric Corporation, Lewistown, PA. ASNT has revised the text in 2010, and deficiencies are not the responsibility of General Electric
Corporation.
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PART 1. Introduction to Indirect Visual Testing

Visual tests comprise five basic elements:


the inspector, the test object,
illumination, a recording method and
Effects of Test Object1,2
usually an optical instrument. Each of The test surface determines the
these elements interacts with the others specifications for (1) the instrument used
and affects the test results. during the visual test and (2) the required
The human eye is an important illumination. Objective distance, object
component for performing visual size, discontinuity size, reflectivity, entry
nondestructive tests. However, there are port size, object depth and direction of
situations where the eye does not have view are all critical aspects of the test
access to the test surface. In these cases object that affect the visual test.
mechanical and optical instruments can 1. Objective distance (Fig. 1) is important
supplement the eye in a family of in determining the illumination
techniques called indirect visual testing. source, as well as the required
Indirect visual testing is sometimes called objective focal distance for the
remote visual testing and is distinct from maximum power and magnification.
direct visual testing, where the inspector 2. Object size, combined with distance,
views the test surface with the naked eye determines what lens angle or field of
and simple magnifiers and gages. Direct view is required to observe an entire
visual testing is discussed in a separate test surface (Fig. 2).
chapter. 3. Discontinuity size determines the
magnification and resolution required
for visual testing. For example, greater
resolution is required to detect hairline
Adjustable Focus1 cracks than to detect undercut (Fig. 3).
Vision acuity affects the visual test, so it is
important for borescopes to allow the
eyepiece to be focused when used, just as
binoculars are. Frequently, eyeglasses are FIGURE 2. Arrows indicate portion of test
inconvenient when the inspector is using object falling within field of view for forward
a borescope: it is difficult to place the eye viewing borescope.
at the ideal distance from the eyepiece,
and the view may be obscured by external
glare and reflections. Rubber eyeshields
on borescopes are designed to shut out
Test object

external light but are not as effective


when glasses are worn. For these reasons, Forward view borescope
it is critical that the inspector be able to
adjust the instrument without wearing Entry port
glasses to compensate for variations in
vision acuity.

FIGURE 1. Objective distance (arrows) for


forward and side viewing borescopes. FIGURE 3. Discontinuity size affects
resolution limits and magnification
requirements.
Side view borescope

Discontinuity
Test object

Forward view borescope


Test object

Entry port

Forward view borescope

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4. Reflectivity is another factor affecting Some of the factors affecting visual


illumination. Dark surfaces such as tests with borescopes are in conflict and
those coated with carbon deposits compromise is often needed. For example,
require higher levels of illumination a wide field of view reduces magnification
than light surfaces do (Fig. 4). but has greater depth of field (Fig. 7). A
5. Entry port size determines the narrow field of view produces higher
maximum diameter of the instrument magnification but results in shallow depth
that can be used for the visual test of field. Interaction of these effects must
(Fig. 5). be considered in determining the
6. Object depth affects focusing. If optimum setup for detection and
portions of the object are in different evaluation of discontinuities in the test
planes, then the borescope must have object.
sufficient focus adjustment or depth of
field to visualize these different planes
sharply (Fig. 6).
7. Direction of view determines Parts of Indirect Visual Test
positioning of the borescope, Instruments
especially with rigid borescopes.
Viewing direction also affects the Instruments for indirect visual testing
required length of the borescope. typically have components for three
functions.
1. A means of illumination is needed for
most applications.
FIGURE 4. Reflectivity helps determine levels 2. A viewing medium conveys or
of illumination. presents the image to the inspector’s
Dark surface
eye.
3. One or more control circuits let the
inspector control a camera’s or
vehicle’s motion.
An instrument widely used for indirect
Forward view borescope
inspections is the borescope, a long
instrument that may be rigid or flexible.
Entry port The distal end has the objective lens
directed at the test surface; the eyepiece,
Light surface or ocular end, is close to the inspector
and may include output to a video screen
for viewing. Many borescopes also
incorporate clamps or tweezers for object
FIGURE 5. Entry port size (arrows) limits size manipulation or retrieval.
of borescope.

FIGURE 7. Effects of viewing angle on other


test parameters: (a) narrow angle with high
magnification and shorter depth of field;
(b) wide angle with low magnification and
Test object

Forward view borescope greater depth of field.

(a)
Entry port

FIGURE 6. Object depth (arrows) is critical


factor affecting focus.
(b)
Test object

Forward view borescope

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Illumination probe may be positioned in real time with


a moving image; then a still image can be
In indirect visual tests, the inspector may recorded to document the inspection.
work in a well lighted area. The test
surface, however, is inside an object or on Telemetric Instrument. In another sort of
the far side of a barrier. Indirect visual video probe, the video signal may be
tests can be classified according to the transmitted as radio signals to a receiver.
source of light that illuminates the test Wireless transmission, however, opens up
surface. a range of possibilities. Such systems have
been used for telemetry and robotics —
1. Light may be ambient in the chamber the remote operation of vehicles such as
— if it is another room, for instance, submarines, aviation drones and outer
or inside an operating furnace. Such space probes. Radio control can permit
applications might include the nondestructive inspector to direct
hydroelectric penstock inspection, for robotic inspections from a distance of
example, but are unusual for most many kilometers.
visual inspectors. Visual test instruments in which a
2. Light may be introduced by a lamp or camera is mounted on a robot or crawler
flash unit at the distal (objective) end are not borescopes, and many of their
of the probing instrument. A lamp can applications, such as marine exploration,3
be powered through a cable integral to are not nondestructive testing.
a borecope. This design is problematic
where there are hazardous fumes.
3. Light may be generated at the ocular
(eyepiece) end of the instrument and Applications of Indirect
conveyed to the test surface through
fiber optic cable. This means of Techniques4
illumination is integral to the design
of virtually all borescopes. Machine Shops
4. A camera based system may operate in
Borescopes find applications in
darkness if the camera is sensitive to
production machine shops, tool and die
infrared or ultraviolet radiation at the
departments and in ferrous, nonferrous
wavelengths of interest. In condition
and alloy foundries. In production
monitoring, for example, an infrared
machine operations, borescopes of various
camera may look for hot spots in an
sizes and angles of view are used to
electric motor. Such applications are
examine internal holes, cross bored holes,
rare for most visual inspectors.
threads, internal surface finishes and
various inaccessible areas encountered in
Image Transmission machine and mechanical assembly
operations. Specific examples are visual
There are various designs for indirect tests of machine gun barrels, rifle bores,
visual testing, and they can be classified cannon bores, machine equipment and
according to the medium used to transmit hydraulic cylinders.
the image from the objective lens to the In tool and die shops, borescopes are
viewing eyepiece or display. used to examine internal finishes, threads,
Rigid Borescope. The light image may be shoulders, recesses, dies, jigs, fixtures,
transmitted through air inside the tube of fittings and the internal mating of
a rigid borescope. This borescope is rigid mechanical parts. In foundries, borescopes
so that the instrument’s stiff body keeps are widely used for internal inspections to
the optical elements (lenses and possibly locate discontinuities, cracks, porosity and
mirrors) aligned. blowholes. Borescopes are also used for
Fiber Optic Borescope. Light may be tests of many types of defense materials,
transmitted through a fiber optic including the internal surface finish of
borescope, having transparent (glass or rocket heads, rocket head seats and guided
plastic) fibers in a cable. A jargon term for missile components.
such an instrument is fiber scope. The
cable is thin, and the cable’s flexibility lets Electric Power Industry
it be threaded around interior corners to
In steam power plants, borescopes are
view surfaces difficult to access. At the
used for visual tests of boiler tubes for
objective end, the image may be captured
pitting, corrosion, scaling or other
by a camera and viewed on a video screen
discontinuities. Borescopes used for this
such as a computer display.
type of work are usually made in 2 or 3 m
Camera Borescope. Light may be sensed (6 or 9 ft) sections. Each section is
by a small camera, converted to an designed so that it can be attached to the
electronic signal and sent through a cable preceding section, providing an
to a video receiver. A single system called instrument of any required length.
a video probe can offer a choice of still Other borescopes are used to examine
photography, motion video or both. The turbine blades, generators, motors,

138 Visual Testing


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pumps, condensers, control panels and blowholes in castings and forgings.


other electrical or mechanical Machined components such as cross
components without dismantling. In bored holes can be examined for internal
nuclear plants, borescopes offer the discontinuities. Borescopes are used to
advantage that the inspector can be in a inspect cylinders for internal surface
low radiation field while the distal, or finish after honing. Tapped holes,
sensor, end is in a high radiation field. shoulders or recesses also can be observed.
Photography of the interiors of large Inaccessible areas of hydraulic systems,
power plant furnaces during operation has small pumps, motors and mechanical or
been done since the 1940s using a electrical assemblies can be visually tested
periscope and camera. The periscope without dismantling the engine.
extends through the furnace wall and
relays the optical image to the camera. A Aviation Industry
water cooled jacket protects the optical
system and the camera from the furnace’s The use of borescopes for tests of airplane
high temperatures. With this equipment, engines and other components without
still and motion picture studies have been disassembly has resulted in substantial
made of the movement of the fuel bed savings in costs and time. A borescope of
and the action of the powdered fuel 11 mm (0.44 in.) diameter by 380 mm
burner in furnaces operating at full load. (15 in.) working length can be used by
maintenance and service departments for
visual testing of engines through spark
Petroleum and Chemical Industry plug openings, without dismantling the
Borescopes are used for visual tests of high engines. An excellent view of the cylinder
pressure catalytic cracking units, wall, piston head, valves and valve seats is
distillation equipment, fractionation possible and several hundred hours of
units, hydrogenation equipment, pressure labor are saved for each engine test. Spare
vessels, retorts, pumps and similar process engines in storage can also be inspected
equipment. Use of the borescope in the for corrosion of cylinder wall surfaces.
examination of such structures is doubly Aircraft propeller blades are visually
significant. Not only does it allow the tested during manufacture. The entire
examination of inaccessible areas without welded seam of a blade can be inspected
the lost time and expense incurred in internally for cracks and other
dismantling, it avoids breakdown and the discontinuities. Propeller hubs, reverse
ensuing costly repair. pitch gearing mechanisms, hydraulic
Visual tests of high pressure distillation cylinders, landing gear mechanisms and
units are used to determine the internal electrical components also can be
condition of tubes or headers. inspected with borescopes. Aircraft wing
Evaporation tubes, fractionation units, spars and struts are inspected for evidence
reaction chambers, cylinders, retorts, of fatigue cracks and rivets and wing
furnaces, combustion chambers, heat sections can be tested visually for
exchangers, pressure vessels and many corrosion. Borescopes used for tests of
other types of chemical process internal wing tank surfaces and wing
equipment are inspected with borescopes corrugations subject to corrosion have
or extension borescopes saved airlines expense by reducing the
Tank cars are inspected for internal time aircraft are out of service.
rust, corrosion and the condition of outlet
valves. Cylinders and drums can be Infrastructure
examined for internal conditions such as
corrosion, rust or other discontinuities. Indirect visual testing is suited for the
interrogation of channels, cavities,
pockets, crevices and interstitial areas in
Automotive Industry all sorts of civil engineering structures. In
Borescopes are widely used in the interior areas, it can look for dampness
manufacturing and maintenance divisions and signs of corrosion, grout in masonry
of the automotive industry. Engine and places where brackets and braces have
cylinders can be examined through spark become detached from structures they are
plug holes without removing the cylinder intended to support. Indirect techniques
head. The cylinder wall, valves and piston can explore air ducts, drains, cisterns,
head can be visually tested for excess water lines, sewers, tunnels, crawl spaces
wear, carbon deposits and surface and wall interiors.
discontinuities. Crankcases and Fiber optic borescopes have been used
crankshafts are examined through wall in the conservation of public statues
plug openings without removing the (Fig. 8)5,6 and to look inside a crypt
crankcase. Transmissions and differentials (Fig. 9).7
are similarly inspected.
Borescopes are also useful for locating
discontinuities such as cracks or

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FIGURE 8. Indirect visual testing of statues: (a) corrosion FIGURE 9. Indirect visual testing of crypt: (a) introduction of
detection5; (b) checking for separation of weld joints in borescope from above; (b) view in borescope eyepiece.7
Statue of Liberty.6
(a)
Fiber optic borescope
(a)
Light source Stone floor
Hidden Drilled hole of church
entrance

(b)

(b)

140 Visual Testing


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PART 2. Borescopy4,8

Focusing of Rigid Borescope


Rigid Borescopes The focus control in a rigid borescope
The rigid borescope (Fig. 10) was invented greatly expands the depth of field over
to inspect the bores of rifles and cannons. nonfocusing or fixed focus designs. At the
It was a thin telescope with a small lamp same time, focusing can help compensate
at the objective end for illumination. for wide variations in eyesight among
Most rigid borescopes now use a fiber inspectors.
optic light guide for illumination. Figures 11 and 12 emphasize the
The image is brought to the eyepiece importance of focus adjustment for
by an optical train consisting of an expanding the depth of field. Figure 11
objective lens, sometimes a prism, relay was taken at a variety of distances with
lenses and an eyepiece lens. The image is fixed focus. Figure 12 was taken at the
not a real image but an aerial image: it is same distances as in Fig. 11 but with a
formed in the air between the lenses. This variable focus, producing sharper images.
means that it is possible both to provide
diopter correction for the observer and to Need for Specifications
control the objective focus with a single
adjustment to the focusing ring at the Because rigid borescopes lack flexibility
eyepiece. and the ability to scan areas,
specifications regarding length, direction
of view and field of view become more
critical for achieving a valid visual test.
FIGURE 10. Lens system in representative rigid borescope. For example, the direction of view should
always be specified in degrees rather than
in letters or words such as north, up,
forward or left. Tolerances should also be
specified.

FIGURE 11. Borescope images with fixed FIGURE 12. Borescope images with variable
focus (compare Fig. 12): (a) at 75 mm focus (compare Fig. 11): (a) 75 mm (3 in.);
(3 in.); (b) at 200 mm (8 in.); (c) at (b) 200 mm (8 in.); (c) 300 mm (12 in.).
300 mm (12 in.).

(a) (a)

(b) (b)

(c) (c)

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Some borescope manufacturers have Miniature Borescope


considered the eyepiece to be zero degrees
One variation of the rigid borescope is
and therefore a direct view rigid borescope
called the miniature borescope. In this
is 180 degrees. Other manufacturers start
design, the relay lens train is replaced
with the borescope tip as 0 degrees and
with a single, solid fiber. The fiber diffuses
then count back toward the eyepiece,
ions in a parabola from the center to the
making a direct view 0 degrees (Fig. 13).
periphery of the housing, giving a graded
index of refraction. Light passes through
Setup of Rigid Borescope the fiber and forms an image at specific
To find the direction and field of view intervals. The aperture is so small that the
during visual testing with a rigid lens has an infinite depth of field (like a
borescope, place a protractor scale on a pinhole camera) and no focusing
board or worktable. Position the mechanism is needed.
borescope parallel to the zero line, with
the lens directly over the center mark on Accessories
the protractor. Remember that the optical
Many accessories are available for rigid
center of a borescope is usually 25 to
borescopes. Still and video cameras can be
50 mm (1 to 2 in.) behind the lens
added to provide a permanent record of a
window.
visual test. Closed circuit television
By sighting through the borescope,
displays are common as well. Also
stick pins into the board at the edge of
available are attachments at the eyepiece
the protractor to mark the center and
permitting dual viewing or right angle
both the left and right edges of the view
viewing for increased accessibility.
field. This simple procedure gives both the
direction of view and the field of view
(Figs. 14 and 15).
Fiber Optic Borescopes
The industrial fiber optic borescope is a
FIGURE 13. Borescope direction of view: flexible, layered sheath protecting two
(a) forward; (b) side; (c) forward oblique; fiber optic bundles, each comprising
(d) retrospective. thousands of glass fibers. One bundle
serves as the image guide, and the other
(a) bundle illuminates the test object.
Light travels in straight lines but
View
optical glass fibers bend light by internal
reflection to carry light around corners
(Fig. 16). Such fibers are 9 to 30 µm
(0.0004 to 0.0013 in.) in diameter,
(b) roughly one tenth of the thickness of a
View
human hair.
A single fiber transmits very little light,
Light but thousands of fibers may be bundled
for transmission of light and images. To

FIGURE 14. Field of view for rigid borescope.

(c) View
60
Light 80 90 80
70 70
60 60
50 50
40 40
30 30
20 20

(d) 10 10
View
0
Light

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FIGURE 15. Distance to test surface versus field of view.

Standard fields of view (degrees)


80 70 60 5550 45 40 30 20 20 30 40 455055 60 70 80

Distance to test surface, m (ft)


50 mm (2 in.)
225 200 175 150 125 100 75 50 25 25 50 75 100 125 150 175 200 225
(9) (8) (7) (6) (5) (4) (3) (2) (1) (1) (2) (3) (4) (5) (6) (7) (8) (9)

Field of view width, mm (in.)

FIGURE 16. Internal reflection of light in FIGURE 17. Light paths in fiber bundles:
optic fiber can be used to move light path (a) uncoated fibers allow light to travel
in curve. laterally through bundle and (b) coated
fibers restrict light’s path to original fiber.
(a)

Cladding

(b) Cladding Core

prevent the light from diffusing, each


fiber consists of a central core of high
quality optical glass coated with a thin
layer of another glass with a different
refractive index (Fig. 17). This cladding
acts as a mirror — all light entering the
end of the fiber is reflected internally as it
travels (Fig. 16) and cannot escape by
passing through the sides to an adjacent
fiber in the bundle. Fiber Image Guides
Although the light is effectively
trapped within each fiber, not all of it The fiber bundle used as an image guide
emerges from the opposite end. Some of (Fig. 18) carries the image formed by the
the light is absorbed by the fiber itself, objective lens at the distal end, or tip, of
and the amount of absorption depends on the borescope back to the ocular end, pr
the length of the fiber and its optical eyepiece. The image guide must be a
quality. For example, plastic fiber can coherent bundle: the individual fibers
transmit light and is less expensive to must be precisely aligned so that they are
produce than optical glass, but plastic is in identical relative positions at their
less efficient in its transmission and is terminations.
unsuitable for fiber optic borescopes. Image guide fibers range from 9 to
17 µm (0.0004 to 0.0007 in.) in diameter.
Their size affects resolution, although the
preciseness of alignment is far more
important.

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A real image forms on both highly diameters, some as small as 3.7 mm


polished faces of the image guide. (0.15 in.), in lengths up to 10 m (30 ft),
Therefore, to focus a fiber optic borescope and with a choice of viewing directions.
for different distances, the objective lens
at the tip must be moved in or out,
usually by remote control at the eyepiece
section. A separate diopter adjustment at Borescope Optical Systems
the eyepiece is necessary to compensate Borescopes are precise optical devices
for differences in eyesight. containing a complex system of prisms,
achromatic lenses and plain lenses that
Fiber Light Guides pass light to the observer with high
efficiency. An integral light source at the
To illuminate the test object, another fiber objective end usually provides
bundle carries light from an external high illumination of the test surface.
intensity source. This light guide bundle
is noncoherent (Fig. 19). These fibers are
about 30 µm (0.0013 in.) in diameter, and Angles of Vision
the size of the bundle is determined by To meet a wide range of visual testing
the diameter of the scope. applications, borescopes are available in
Fiber optic borescopes usually have a various diameters and working lengths to
controllable bending section near the tip provide various angles of vision for special
so that the inspector can direct the requirements. The most common vision
borescope during testing and can scan an angles are (1) right angle, (2) forward
area inside the test object. Fiber optic oblique, (3) direct and (4) retrospective
borescopes are made in a variety of (Fig. 13).
These types of vision are characterized
by different angles of obliquity for the
FIGURE 18. Optical fiber bundle used as image guide. central ray of the visual field, with respect
to the forward direction of the borescope
axis (Table 1).
Fiber bundle

General Characteristics
Desirable properties of borescopic systems
are large field of vision, no image
distortion, accurate transmission of color
values and adequate illumination.
The brightest images are obtained with
borescopes of large diameter and short
Objective
length. As the length of the borescope is
Eyepiece
increased, the image becomes less brilliant

FIGURE 19. Diagram of representative fiber optic borescope.

Eyepiece Focusing ring


lens

Image
guide Objective lens

Light guide Protective sheath

Diopter ring
Light guide exit
Light source

Projection lamp

144 Visual Testing


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because of light losses from additional very small compared with that of a
lenses required to transmit the image. To microscope, the corresponding depth of
minimize such losses, lenses are typically focus is exceedingly large. This permits
coated with antireflecting layers to the use of fixed focus eyepieces in many
provide maximum light transmission. small and moderately sized instruments.
Focus and field of view are discussed in
Optical Components the chapter on photography.
The total magnification of borescopes
The optical system of a borescope consists varies with diameter and length but
of an objective end, a middle lens system, generally ranges from about 2× to 8× in
correcting prisms and an ocular section use. Note that the linear magnification of
(Figs. 10 and 19), angle of vision, the field a given borescope changes with working
of view and the amount of light gathered distance and is about inversely
by the system. proportional to the object distance. A
The middle lenses conserve the light borescope with 2× magnification at
entering the system and conduct it 25 mm (1 in.) working distance therefore
through the borescope tube to the eye will magnify 4× at 13 mm (0.5 in.)
with a minimum loss in transmission. distance. Magnification is discussed in the
Design of the middle lenses has an chapter on direct viewing.
important effect on the character of the
image. For this reason, the middle lenses
are achromatic, each lens being composed
of two elements with specific curvatures Borescope Construction
and indexes of refraction. This design A borescopic system usually consists of
preserves sharpness of the image and true one or more borescopes having integral or
color values. attached illumination, additional sections
Depending on the length of the or extensions, a battery handle, battery
borescope, the image may need reversal or box or transformer power supply and
inversion or both, at the ocular end. This extra lamps, all designed to fit in a
change is accomplished by a correcting portable case. If light is provided by a
prism within the ocular end for lamp at the objective end, insulated wires
borescopes of small diameter and by between the inner and outer tubes of the
erecting lenses for larger designs. borescope serve as electrical connections.
A contact ring permits rotation of the
Depth of Focus, Field of View and borescope through 360 degrees for
Magnification scanning the object space without
entangling the electrical cord. In most
The depth of focus for a borescopic designs, however, illumination is provided
system is inversely related to the by fiber optic light guides (Fig. 19).
numerical aperture of its lens. Field of Borescopes with diameters under
view, on the other hand, is relatively 38 mm (1.5 in.) are usually made in
large, generally on the order of 50 degrees sections, with focusing eyepieces,
of angular field. This corresponds to a interchangeable objectives and high
visual field of about 25 mm (1 in.) power integral lamps. This kind of
diameter at 25 mm (1 in.) from the borescope typically consists of an eyepiece
objective lens. At different working or ocular section, a 1 or 2 m (3 or 6 ft)
distances, the diameter of the field of view objective section, with 1, 2 or 3 m (3, 6 or
varies with the working distance (Figs. 14 9 ft) extension sections. The extensions
and 15). are threaded for fitting and ring contacts
The entrance pupil is that image of any are incorporated in the junctions for
of the lens apertures, imaged in the object electrical connections. Special optics can
space, which subtends the smallest angle be added to increase magnification when
at the object plane. Because the numerical the object is viewed at a distance.
aperture of borescope systems is usually Angulated borescopes are available
with forward oblique, right angle or
retrospective visual systems. These
TABLE 1. View orientations and angles of obliquity. instruments usually consist of an
objective section with provision for
Orientation Angle of Obliquity Angular Field attaching an eyepiece at right angles to
(degrees) (degrees) the objective section’s axis. This permits
Direct 0 45 inspection of shoulders or recesses in
Forward oblique 25 50 areas not accessible with standard
Forward 45 45 borescopes. Eyepiece extensions at right
angles to the axis of the borescope can be
Right angle 90 50
supplied, with provision to rotate the
Retrospective 135 45
borescope with respect to the eyepiece
Circumferential 0 and 90 45 to 15 extension, for scanning the object field.

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Right Angle Borescopes Panoramic Borescopes


The right angle borescope can have a light Wide field borescopes have rotating
source positioned ahead of the objective objective prisms to provide fields of view
lens. The optical system provides vision at up to 120 degrees. One application of
right angles to the axis of the borescope wide field borescopes is the observation of
and covers a working field of about models in wind tunnels under difficult
25 mm (1 in.) diameter at 25 mm (1 in.) operating conditions.
from the objective lens. Special optical systems permit rapid
Applications of the right angle panoramic scanning of internal surfaces.
borescope are widespread. The instrument A mirror mounted in front of the
permits testing of inaccessible corners and objective lens system is rotated by turning
internal surfaces. It is available in a wide a knob near the eyepiece. Swiveling in
range of lengths, in large diameters or for one plane covers the ranges of forward
insertion into apertures as small as oblique, right angle and retrospective
2.3 mm (0.09 in.). It is the ideal vision.
instrument for visual tests of rifle and One form of panoramic borescope
pistol barrels, walls of cylindrical or permits rapid scanning of the internal
recessed holes and similar components. cylindrical surfaces of tubes or pipes. This
Another application of the right angle instrument has a unique objective system
borescope is inspection of the internal that simultaneously covers a cylindrical
entrance of cross holes, where it may be strip 30 degrees wide around the entire
critical to detect and remove burrs and 360 degrees with respect to the axis of the
similar irregularities that interfere with borescope. The diameter of this
correct service. Drilled oil leads in castings instrument is 25 mm (1 in.) and the
can be visually inspected, immediately working length is 1 m (3 ft) or larger.
following the drilling operation, for
blowholes or other discontinuities that Sectioned Borescopes
cause rejection of the component. Right
angle borescopes can be equipped with Borescopes under 38 mm (1.5 in.)
fixtures to provide fast routine tests of diameter are often made in pieces, with
parts in production. The device’s the objective section 1 or 2 m (3 or 6 ft)
portability allows occasional tests to be in length. The additional sections are 1, 2
made at any point in a machining cycle. or 3 m (3, 6 or 9 ft) long with threaded
connections. These sections may be added
to form borescopes with lengths up to
Direct Vision Borescope 15 m (45 ft) for diameters under 38 mm
The direct vision instrument provides a (1.5 in.).
view directly forward with a typical visual
area of about 19 mm (0.75 in.) at 25 mm Special Purpose Borescopes
(1 in.) distance from the objective lens.
The light carrier is removable so that the Borescopes can be built to meet many
two parts can be passed successively special visual testing requirements. The
through a small opening. factors affecting the need for custom
designs include: (1) the length and
position of the test area, (2) its distance
Forward Oblique Borescopes from the entry port, (3) the diameter and
The forward oblique system is a design location of the entry port and
that permits the mounting of a light (4) inspector distance from the entry port.
source at the end of the borescope yet also Environmental conditions such as
allows forward and oblique vision temperature, pressure, water immersion,
extending to an angle of about 55 degrees chemical vapors or ionizing radiation are
from the axis of the borescope. important design factors. The range of
A unique feature of this optical system special applications is partly illustrated by
is that, by rotating the borescope, the the examples given below.
working area of the visual field is greatly Miniature Borescopes. Miniature
enlarged. borescopes are made in diameters as small
as 1.75 mm (0.07 in.), including the light
Retrospective Borescope source. They are useful because they can
go into small holes. Inspection of
The retrospective borescope has an
microwave guide tubing is a typical
integral light source mounted slightly to
application.
the rear of the objective lens. For a bore
with an internal shoulder whose surfaces Periscopes. A large, multiangulated,
must be accurately tooled, the periscope with a right angle eyepiece and
retrospective borescope provides a unique a scanning prism at the objective end,
method of accurate visual inspection. with field of view 70 degrees in azimuth
by 115 degrees in elevation, has been used

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for remote observation of otherwise these instruments can be calibrated to


inaccessible areas — cave exploration, for indicate the depth of insertion during a
example.8 test. Borescopes with calibrated reticles are
Indexing Borescope. Butt welds in pipes used to determine angles or sizes of
or tubing 200 mm (8 in.) in diameter or objects in the field when held at a
larger can be visually tested with a special predetermined working distance.
90 degree indexing borescope. The Ultraviolet Borescopes. Ultraviolet
instrument is inserted in extended form borescopes are used during fluorescent
through a small hole drilled next to the magnetic particle and fluorescent
weld seam and is then indexed to the penetrant tests. These borescopes are
90 degree position by rotation of a knob equipped with ultraviolet lamps, filters
at the eyepiece. The objective head is then and special transformers to provide the
centered within the tube for viewing the necessary wavelengths.
weld. A second knob at the eyepiece Harsh Environments. Waterproof and
rotates the objective head through vaporproof borescopes are used for
360 degrees for scanning the weld seam. internal tests of liquid, gas or vapor
Reading Borescopes. Low power reading environments. They are completely sealed
borescopes are used in plant or laboratory and impervious to water or other types of
setups for viewing the scales of liquid. Water cooled or gas cooled
instruments such as cathetometers at borescopes are used for tests of furnace
inaccessible locations. The magnification cavities and jet engine test cells and for
is about 3× at 1 m (3 ft) distance. other high temperature applications.
Calibrated Borescopes. Calibrated
borescopes are designed to meet specific
test requirements. The external tubes of

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PART 3. Camera Based Measurement 9

it may be too flexible to probe very long


Video Borescope distances. Similarly, stiff bundles can
probe farther but do not bend easily.
Relatively small openings can be accessed Small diameter tubes, pipe or openings
by using a charge coupled device sensor, into piping or tubing systems, pumps,
light transmitted through a fiber bundle valves, turbines, gear boxes or other
to the test surface (Fig. 20). The returning components may be accessed if there are
image is passed electronically from the no multiple sharp turns for distances
charge coupled device through a wire to longer than several feet.
the image processor. From the processor, Video borecopes are often called video
the reconstructed pixel image is viewed probes or video scopes to distinguish them
on a monitor, typically a liquid crystal from fiber optic borescopes, which they
display. resemble.
Small openings from 6 to 80 mm
(0.25 to 3.0 in.) may be penetrated with
the probe. Skillful manipulation can gain
access to awkward locations not in the Characteristics Measured
initial line of sight.
In indirect visual testing, the test surface
The total distance from the tip to the
is typically the interior of a text object —
test surface is limited by the fiber bundle
for example, the inside surface of a pipe.
transmitting the light. If a the bundle is
To characterize or describe a feature, there
flexible enough to make sharp turns, then
are several ways that its shape, orientation
or extent can be measured on that test
surface.
FIGURE 20. Video probe: (a) tip; 1. A distance measurement is a linear
(b) attachments. measurement of objects on a flat
surface perpendicular to the optical
(a) axis of the probe. (Note that the word
distance here does not mean distance
from the probe to the surface.)
2. A skew measurement is a linear
measurement of an object on a surface
at an angle that is skewed, or
nonperpendicular, to the optical axis
of the probe (Fig. 21).

FIGURE 21. Skew measurement is linear


measurement of object on surface at
skewed angle (nonperpendicular) to optical
axis of probe.

(b)
Grabber 127 µm
8 mm comparison
magnet Brush measurement
Alligator gage
Hook

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3. A depth measurement measures the 7. Point-to-line measurement provides


height or depth of an object by data in two dimensions, along an X
determining the distances from the axis and Y axis. The length of a line
probe to nearer and farther surfaces perpendicular to a line between two
and calculating the difference. The points is measured.
viewing angle should be perpendicular
to the surface plane (Fig. 22) or the
resulting measurement will be a
diagonal distance rather than normal FIGURE 23. Cursors are connected to
distance. measure size or area of discontinuity on flat
4. Area measurement calculates the surface perpendicular to optical axis.
surface area of a discontinuity or
feature in a plane. The operator places
multiple cursors in the image so that
the dots when connected encompass
the area of interest — a surface feature
or anomaly (Fig. 23). Using image
processing programming, the
microprocessor calculates the surface
area encompassed. Area measurement
can be used to measure variations in
material or surface conditions, for
example, a patch of corrosion.
5. A circle gage (Fig. 24) is a quick and
convenient way to check that a
feature’s diameter does not exceed a
set amount in any direction. A circle is
drawn and saved in the computer
memory and may be superimposed on FIGURE 24. Circle gage technique makes
the test image during discontinuity circle of known size on image to compare to
assessment. A circle gage is like a feature, based on known reference
reference object’s image stored in the dimension.
optical instrument’s microprocessor. It
can be used with the stereo or shadow
techniques and is useful for quick
accept/reject measurements.
6. Multiple short segments can be
combined to measure the length of a
nonlinear feature (Fig. 25). Segment
lengths are calculated from point to
point; the actual length depends on
cursor placement and so may not
follow the surface of the object.

FIGURE 22. Depth measurement measures


height or depth of object by determining
distances from probe to upper and lower
surfaces and calculating difference.
FIGURE 25. Multiple-segment technique is
used to measure length of nonlinear feature
by combining lengths of shorter segments.

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Note that commercially available A reference block can be used to verify


systems do not display the distance from measurement accuracy. One such
the probe to the surface. Integral software measurement verification block contains a
makes that calculation automatically and side view chamber and one forward view
provides the inspector with data of chamber that contains 2.5400 mm ±
interest — the size or extent of 0.00508 mm (0.100 ± 0.0002 in.) test
discontinuities or surface features. targets having calibration traceable to
reference standards of the National
Institute of Standards and Technology.

Principles of Measurement
There are several designs that permit
optical systems to measure objects and Techniques of
indications in the field of view. Three Measurement
fundamental approaches may be used in The three means of measurement —
combination: (1) triangulation, triangulation, comparison and pixel
(2) comparison with a reference object (in counting — are used in various
the field of view or memory) and (3) pixel combinations by three significant
counting. measurement techniques: stereo, shadow
and comparison (Table 2).
Triangulation
Indirect systems incorporate calibrated
lens assemblies and image processing FIGURE 26. Triangulation.
programs to perform measurements
automatically, so the visual inspector does Object
not need to learn trigonometry to
measure indications. Understanding the
principles behind the measurement,
however, is valuable for purposes of test
planning and interpretation.
Triangulation has been used for
indirect measurements for centuries. The
tangent of an angle is the ratio of the side
opposite the angle divided by the side
adjacent to the angle. The adjacent side is
Distance
the inspector’s position, and the opposite to test
side is the distance to the object (Fig. 26). surface
Using a calculator with a tangent
function, the inspector can set up a ratio
and solve for the distance to the object.
For example, given a right triangle with
an adjacent side of 10 m and a side angle
of 70 degrees, what is the target
distance X?
90 degrees
70 degrees
Opposite side
(1) Tan = Viewer or
Adjacent side probe 10 m

X
(2) Tan 70 = 2.7475 =
10 m

X = 27.5 m TABLE 2. Measurement techniques for indirect visual


(3) testing.
Techniques
____________________________________
Accuracy Measurement Stereo Shadow Comparison
The accuracy of any measurement
depends on the ability of an operator to Distance (length) yes yes yes
operate the instrument and to recognize Skew — yes —
and capture a quality image. Accuracy is Depth yes yes —
maximized by using the greatest Area yes yes yes
magnification (filling as much of the Circle gage — yes yes
screen as possible with the image), getting Multiple-segment yes yes yes
as close to perpendicular as possible and
Point to line yes yes yes
accurately placing the measurement
cursors.

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Stereo Measurement computer memory or frozen at the


moment of inspection. The shift of the
A stereoscopic image is a picture
shadow cast across the face of the image
comprising two images of the same scene,
permits trigonometric calculation of the
taken from different viewpoints slightly
distance to the surface on which the
displaced from each other, the viewpoints
shadow lies. The points across the plane
corresponding to the eyes right and left
of the surface can be calculated by placing
(Fig. 27). Some indirect visual test systems
a cursor on different points of the shadow
capture the twin images by offsetting one
or points on a plane of the measured
lens by a small, known distance. An
feature.
inspector must view a stereoscopic image
The shadow is cast by a gnomon in the
with both eyes to get stereo effect.
optical instrument. (The term gnomon
Parallax is the apparent motion of a
denotes the blade or column that casts a
relatively close object with respect to a
shadow on the face of a sundial; here, it
more distant background as the location
denotes an artifact in the illumination
of the observer changes. This apparent
system that casts a shadow on the test
displacement of an object is discussed also
surface.) If the size of the gnomon is
in this volume’s section on
known, its shadow can be used to
photogrammetry. Stereoscopic parallax is
measure a feature on the test surface. In
caused by taking photographs of the same
this case as in others, the calibrated
object but from different points of
system makes calculations and
observation. Adjacent but overlapping
automatically provides measurements to
photograph pairs can be used to measure
the inspector.
depth and feature dimensions.
Measurement can be made even if the
The difference in the angles formed by
objective is so close to a surface that the
the lines of sight to two objects at
image is somewhat out of focus. In this
different distances from the eyes is a
case, features must be sharp enough so
factor in the visual perception of depth.
that the cursors can be placed accurately.
Parallax is inversely proportional to an
There are various implementations of the
object’s distance. An object near the
inspector’s nose has a much larger
parallax than an object at arm’s length
A stereo probe provides two views FIGURE 27. Stereo technique: (a) setup; (b) variation of
simultaneously on the left and right side parallax with distance of three different objects.
of the screen. The farther something is
(a)
from the observer, the less it appears to
move in one view than in the other. The Aperture
Camera
computer needs to recognize enough of a sensors Lens Light guide Splitting lens
unique image in one view to recognize it
Object
in the adjacent view. The computer uses
triangulation geometry to perform
measurements. The shift is measured, and
the distance is calculated. The shift in
pixel distance between two cursors on an Two images
image plane from one stereo view and the Head assembly Stereo tip
other gives the ability to calculate
distances. (b)
There are five implementations of
stereo measurement: length, point to line, Stereo views
area, multiple-segment length and circle C
Far
gage.
The accuracy of stereo probe
measurements depends on operator skill, B
C C
image quality and magnification. The
Fields of
usable range for performing stereo view
measurements extends out to a target
distance of about 30 mm (1.25 in.). For A
more accurate measurements, it is B B
recommended that measurements be
performed with a distance of 15 mm
(0.64 in.) from tip to target. Probe

Shadow Measurement A A
A known distance of a light source to an
offset from the center hairline obstruction Near
yields a known angle of the shadow being Left Right
cast (Fig. 28). A shadow measurement is
made with an image recalled from

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shadow technique, including distance, left to indicate a raised surface or to the


skew, depth, point-to-line length, right to indicate a recessed surface. Depth
multiple-segment length, area and circle measurements can only be made along
gage. the shadow, so the shadow should be
The measurement surface must be aligned vertically across the change in
nearly perpendicular to the probe view for contour before freezing or capturing the
an accurate measurement, except for skew image. When marking the depth or height
measurements. The axis is perpendicular if to be measured, place the point cursors
the shadow appears in the viewer as an along the center of the shadow on the
unbroken line that remains vertical even lower and upper surfaces near the depth
when the objective head is rotated. In this break.
viewing condition, measurements can be To ensure accuracy, the operator must
taken anywhere in the frozen image. place the cursor on the shadow image
In skew measurements, the shadow will consistently.
appear sloped, nonvertical, indicating that
the distance from the surface to the probe Comparison Measurement
(and therefore magnification) varies. From
a skewed viewing angle, measurements Comparison measurements are made by
can be made only along the shadow, so using saved images. Measurement begins
the shadow must be aligned with the by measuring the dimension of a known
object to be measured before the image is reference object or feature (placed on the
captured and the measurement is made. A test surface with the probe or previously)
sloped shadow means the viewing tip is to measure other objects in the same view
not perpendicular to the surface, so and plane. These reference images must
distance to the surface and magnification be at same focal distance to the test
differ in different parts of the image. surface, and the measurement surface
In depth measurements, when the must be nearly perpendicular to the probe
surface planes are perpendicular, the for accuracy. Pixels in the image are then
shadow will appear vertical in the image counted to measure feature areas and
and remain vertical even when the probe dimensions.
is rotated. The shadow will break to the The comparison technique is suited for
measuring feature characteristics for their
length, point-to-line distance,
multiple-segment length, area and circle
FIGURE 28. In the shadow technique, the probe tip contains
gage diameter. Although less accurate
a charge coupled device imager with lens and fiber optic
than shadow or stereo measurements,
bundle carrying illumination from light source. The
comparison measurements are useful if a
illumination lens has a gnomon on it that casts a shadow
shadow or stereo tip is unavailable, if the
into field of view.
area or feature to be measured is too far
for the shadow or stereo technique, if a
shadow cannot be placed where needed, if
the computer will not match two stereo
Probe head Illumination images or if the approximate sizes of
many items are to be checked quickly.
Gnomon Measurement tips can be calibrated for
specific probes and might not measure
Fiber
accurately with other probes. For
optic optimum accuracy, stable seating of the
light measurement tips can be ensured by small
O rings on the probe tip. The O ring
6.1 mm should be checked each time the
probe Camera measurement tip is used, and it must be
imager
replaced if missing or excessively worn.

Shadow Depth Measurement


Image field of view
A depth measurement calculates the
distance of a point above or below a plane
surface. In the stereo technique, software
D1 D2 requires the user to place three cursors on
the image to define a plane surface and
then to place a fourth cursor above or
below that plane. The microprocessor will
calculate the length of a perpendicular
line between the fourth cursor and the
Shadow falls defined plane.

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In the shadow technique (Fig. 22), and lens options to perform a variety of
depth can only be measured along the inspections with one video system.
shadow, so the shadow should be aligned Applications are found in the
vertically across the change in contour infrastructure, processing, power
before freezing the image. When marking generation and water treatment
the depth or height to be measured, the industries. A single system inspects
point cursors should be placed along the stainless tubing for weld condition or
center of the shadow on the lower and cleanliness, process piping, drain lines
upper surfaces near the break. When the and heat exchangers. Camera heads can
surface planes are perpendicular, the be swapped for different pipe openings
shadow will appear vertical in the image and diameters.
and remain vertical even when the probe The push camera design is unsuited for
is rotated. The viewing angle should be large diameter channels or open spaces
perpendicular to the surface plane to yield where specific directional views are
a true vertical depth. desired. Without pan, tilt and zoom
capabilities, the view obtained yields
minimum choice by the operator.
Fossil Power Generation. The push camera
Access to Particular is suited for inspections of headers,
Viewpoints turbines, boiler tubes, drain lines, heat
Several designs have the specific function exchangers, steam drums and other
of maneuvering the camera to where it confined spaces. Varying lenses and
can view an area of interest. camera heads provide flexibility for the
specific situations.
Pan, Tilt and Zoom Cameras Water Treatment. The push camera
facilitates quick inspections of confined
Cameras that can pan, tilt and zoom areas such as steam drums. One hand is
(Fig. 29) facilitate inspections by directing used for camera operation; the other, for
the camera on specific areas of interest. In viewing and control functions up to 50 m
the nuclear industry, these systems are (164 ft) away. A color camera provides
used for inspection or surveillance color images to help identify water and
activities in refueling, reactor vessel steam related corrosion in pipe diameters
maintenance and inservice inspections. from 31.8 mm (1.25 in.) to 406 mm
Loose parts, tools or debris dropped into (16 in.).
power generation systems may be
retrieved from hard-to-reach areas without
disassembly of plant equipment.
The pan, tilt and zoom camera is suited FIGURE 29. Camera head with pan, tilt and
for surveillance, large diameter piping, zoom capabilities.
on-line applications, radiation
environments, underwater applications,
sumps, manifolds, and steam headers.
The pan, tilt and zoom camera is not
suited for small diameter piping, heat
exchangers or the space between the core
shroud and the reactor vessel.
Panning, tilting and zooming permit
the indirect viewing of vessels for
cleanliness, corrosion, discontinuities,
interior indications of cracks and many
other features of the vessel surface. The
collection of digital images of the
inspection allows for historical
comparisons of previous vessel
inspections to identify and track changes
of tanks or vessel profiles.

Push Cameras
A “push” camera is mounted on a rigid
rod that the inspector inserts into an
aperture or cavity; additional rods can be
attached to extend the total length. A
separate electronics cable controls the
camera and carries images to the inspector
or work station. A push camera can be
adapted to various applications with
specific cable lengths, camera diameters

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Infrastructure. The structural integrity of a A crawler with 300 mm (12 in.) wheels
building or the condition of a heavily and 13.6 kg (30 lb) of pull power can
trafficked bridge can be checked with examine 200 mm (8 in.) and larger pipes
accuracy and accessibility. Hand held and distances up to about 450 m
operation and varying cable lengths allow (1500 ft). This arrangement allows
for remote viewing in wastewater systems, operation in hazardous environments and
buildings, bridges, underground piping, 24× zoomed viewing up to 15 m (50 ft)
manholes and building airshafts. from the camera.
Large tractors can carry the camera,
Crawlers lights, pull cable and pan and tilt
mechanism — up to 9.5 kg (21 lb) — for
Crawlers are useful for pipe inspections distances up to 200 m (600 ft) long. As a
and entrances to hazardous spaces. Pipe rule, it is better to use the more stout
crawler camera systems are commonly system when space and configuration
made of a tractor, lights, a camera (with allow. The wheels can be removed to fit
or without pan and tilt), a cable reel, 250 mm (10 in.) pipe, but crawlers still
central control unit and various need room to make a turn.
accessories and controls including Adverse terrain can be navigated, and
auxiliary lights and centering devices. The steep inclines can be negotiated. Some
typical combination is tractor, light, debris can be tolerated in the pipe or
camera and cable (Fig. 30). tank, and some bumps can be overcome,
When space permits, robotic crawlers but a crawler needs clearance to get over
are available with options to mount a an obstacle. After the crawler gets over
charge coupled device camera with two debris in the outbound travel, it can be
35 W spot or flood lamps. The pan, tilt difficult to retrieve it over the same debris
and zoom armatures of the camera can be if the downstream or far side of an
mounted atop a robotic crawling platform obstruction is not tapered for the return
or axially in front of a crawler. trip (Fig. 31).
Many robotic crawlers are portable and Crawlers can explore enclosed spaces
designed to inspect inside pipes with and channels such as air ducts and
diameters ranging from 150 mm (6 in.) to electrical conduits, lubrication oil lines,
900 mm (36 in.). Crawlers can pass steam lines, steam headers and small
through restricted pipe, large offsets, and pressure vessels and tanks. If waterproof,
protruding pipe taps. crawlers are suited for environments that
may have liquid up to 100 mm (up to
4 in.) deep— sewer lines, concrete pipe
FIGURE 30. Video probe crawler: (a) side diagram; storm lines and intake or discharge lines.
(b) application photograph. A variety of wheel assemblies are available
for retrieving loose parts and
(a) Camera
maneuvering through wreckage.

Cable connector

FIGURE 31. Obstruction must be tapered to permit travel


over it: (a) obstruction with taper for travel to left but not to
right; (b) minor obstruction.
(a)

Strain relief Direction of travel


Debris or obstacle

(b)

(b)
Direction of travel

Debris or obstacle

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References

1. Section 4, “Basic Aids and Accessories


for Visual Testing”: Part 1, “Basic
Visual Aids.” Nondestructive Testing
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