What is Non-Destructive Testing?
Heavy fabrication weld integrity is critical to the success and longevity of heavy projects in the field. One way that machine shops ensure the quality assurance of heavy parts is with a thorough and effective inspection program. A common method used to confirm quality is Non-Destructive Testing (NDT), also referred to as Non-Destructive Examination (NDE) or Non-Destructive Inspection (NDI). NDT covers a wide range of inspection techniques that are used across a variety of industries – all of which allow inspectors to assess the structural integrity of a part without damaging it. For the purpose of this article, we will focus on the NDT of welds.
Destructive versus Non-Destructive Testing
When it comes to testing and inspections, there are two main types used to assess a weld: destructive and non-destructive. Destructive testing pushes the weld to the point of failure via a variety of methods to assess properties such as compression, fatigue, and tensile. This form of testing is often used on a sample size of parts to assess the ability of a type of weld to meet or exceed a given set of specifications or requirements. As the name implies, destructive testing damages, alters, and often destroys the part and is, therefore, costly. Conversely, non-destructive testing does not damage or compromise the part and is a tool used to determine potential issues or flaws in a weld, and to establish the viability of a part while minimizing risk. NDT inspections can detect the presence of cracks, slag, or stresses caused by environmental conditions like humidity.
NDT for Heavy Fabrications
NDT methods are used to inspect a weld and are common practice for heavy fabrication projects. This level of inspection is necessary as the welding process can result in defects due to metallurgical changes caused by the extreme heat and welding conditions – and visual inspections are often not able to detect defects or the internal flaws of a weld. The purpose of non-destructive testing is to identify potential issues on the surface or within the weld that may result in performance issues including failure. These tests are able to identify potential density or porosity issues as well as cracks within a weld that could lead to a break or rupture. Failure of a weld could have significant consequences so weld integrity is a critical aspect of heavy fabrications that must be properly managed.
There are several different NDT techniques that vary in the level of time, equipment, and cost required to perform the test. Many NDT methods involve high-speed scanning or imaging or rely on feedback signals such as sound or electromagnetic radiation to evaluate the integrity of a part. Common NDTs for weld inspections include ultrasonic, magnetic particle, eddy current, dye penetrant, and radiography. Ultrasonic NDT is one of the most prevalent practices and provides high quality results quickly without much setup required. NDT inspection technologies have advanced in recent years and are able to provide accurate weld inspections along even more challenging geometries and rough surfaces.
Looking for a proven heavy fabrication partner that provides a complete solution for your next project?
Contact ABS to learn about our state-of-the-art facilities, including CNC machining, testing, and assembly as well as our unwavering commitment to quality.
Benefits of NDT in Heavy Fabrications
There are several benefits of non-destructive testing of welds. First and foremost, with NDT the heavy fabrication being inspected is not damaged or compromised by the testing – avoiding costly replacement or repair costs. NDT methods are accurate and yield reliable results. OEMs can rely on NDT inspections for precise weld quality analysis.
In recent years, the digitalization of manufacturing associated with Industry 4.0 has become increasingly prevalent in machine shops including NDT technologies. Today’s NDT equipment offers more functionality and are often equipped with internet connectivity and other necessary hardware like sensors or processors that measure and report data via the internet. This form of smart manufacturing is changing machine shops by enabling the acquisition and accessibility of far greater amounts of data, at far greater speeds, and far more efficiently than before. Current generations of NDT have higher sensitivity that discovers minute weld flaws previously unrecognized and are able to quickly interpret data using advanced software.
Another benefit of Industry 4.0 is the miniaturization of electronic devices. NDT equipment is becoming smaller and more compact with more processing power and functionality. NDT technologies are often portable and inspectors are able to perform the inspection, analysis of the data, and report the results autonomously without the need for additional software or equipment. This advancement provides more timely results and gives real-time feedback to machine shop operators – yielding a more cost-effective solution compared to prior NDT generations.
ABS’ Approach to Quality Testing for Heavy Fabrications
At ABS, we serve markets worldwide with precision machining and assembly capabilities. Our CNC machining capability coupled with our expert machining staff and engineers give us the extra edge to provide you with any large size project your company is undertaking. Our commitment at ABS is to provide continuous improvement and customer satisfaction with every service we offer. We achieve this by assuring that our processes, operations and employees all operate under the ISO 9001:2015 system of quality management. Reliable and repeatable inspection results are assured with highly experienced dedicated QC staff and comprehensive quality procedures, using state-of-the-art CMM technology in a purposely built QC room. Quality is part of our culture and not an afterthought.
The team at ABS assemble custom products and help reduce your overall assembling cost based on your specifications. OEMs using our contract assembly services can lower their overall production costs as well as reduce lead-time to market. If you’re looking for a machining partner that you can trust for high quality and on-time delivery, ABS Machining is your best choice. Our assembly services include:
- Load Testing
- Function Testing
- Priming, painting and coating or parts and assemblies.
- Testing components using mechanical, electrical and NDT testing
- Onsite inspection including X-Ray, LPI, MPI
About ABS
Established in 1971, ABS Machining has grown to become the recognized global leader in large CNC machining, fabrication, and assembly for OEMs. The key to our success has been exceptional people, unparalleled facilities, and an unwavering commitment to quality. Our people are experts in their given field. Their expertise is matched only by their passion for serving our clients. We continue to invest in our people with education programs, cross training and in our internal accredited apprenticeship center.
Our facilities are state-of-the-art and we are equipped to serve our client’s requirements in:
Our massive fleet of machines and automated welding systems has delivered solutions to the most technically challenging projects. Our commitment to maintaining unparalleled facilities is evidenced by our renowned continuous capital reinvestment initiatives. Our commitment to quality goes well beyond our ISO 9001:2015 Registration. From the inception of all programs, ABS quality professionals work closely with each customer to ensure all their unique requirements are met or exceeded. It is this commitment that has positioned ABS as a strategic supplier to leading OEMs worldwide.
Contact us today to see how we can help with your machining project, or give us a call at 1-844-227-6224.
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