Standards-compliant visual testing of weld geometries on components with safety relevance
Weld Inspection

Standards-compliant visual testing of weld geometries on safety-relevant components

Automated app-based workflow – from measurement planning to complete documentation

  • Faster and easier visual testing than conventional methods
  • Weld geometries are checked automatically
  • Traceable inspection results, free from user interpretation

Between complex standards and testing obligations

Whether in trains, heavy equipment, or bridges – wherever components are exposed to high loads, weld quality is critical to structural safety. In many cases, visual testing of welds (VT) is a legal requirement as part of quality control. It must be performed in accordance with applicable standards, such as DIN EN ISO 5817. For inspectors, this can be a demanding and time-consuming task.

Selected industries

Standards-compliant visual testing of welds (VT) is mandated in industries such as:
Heavy Equipment

Heavy equipment

Heavy-duty components are exposed to constant mechanical stress and vibration. Visual testing plays a key role in detecting critical weld flaws and preventing structural failure.

Wind Energy

Wind energy

Wind turbine monopiles contain a large number of critical welds – from segment connections to internal attachments like sockets and mounting brackets. Each weld must be thoroughly inspected to ensure structural integrity.

Oil & Gas

Oil & gas

Pipelines, pressure vessels, and structural components operate under high pressure, temperature fluctuations, and/or corrosive environments. Every weld must be checked to prevent leaks, shutdowns, or even catastrophic failures.

Bridge Construction

Bridge construction

Before and after assembly, all structural welds on prefabricated steel components undergo visual testing to ensure the bridge’s long-term safety and durability.

Key challenges in visual weld testing

  • Complex standards

    Complex standards

    Evolving standards are confusing and full of cross-references and exceptions – navigating them takes time, and remembering every detail is nearly impossible.

  • Evidence of compliance

    Evidence of compliance

    Creating traceable data and reliable documentation is costly – yet essential to prove inspections were carried out correctly.

  • Measurement accuracy

    Measurement accuracy

    Depending on the measuring method applied, measurement results can be inconsistent and hard to reproduce.

Our solution: Weld Check

Automate your visual testing of weld geometries with the Weld Check app for ZEISS INSPECT. It applies standards, ensures traceability, and eliminates manual interpretation.
Digital workflow for VT tasks

Digital workflow for VT tasks

The Weld Check app is a powerful tool for digital visual testing of weld geometries. With a single click, welds can be evaluated directly in a 3D scan according to applicable standards (e.g., DIN EN ISO 5817). The entire inspection process runs automatically, significantly reducing the workload for the inspector.

The solution also enables comprehensive reporting of all weld characteristics – making visual inspections fully consistent and traceable.

Your benefits

Digital visual testing (VT) of weld geometries with full traceability – accurate, standards-compliant, and efficient
Automated testing workflow

Automated testing workflow

In Weld Check, you select the applicable standard (e.g., DIN EN ISO 5817) as well as the required evaluation group (B, C, or D) — and the analysis of all relevant inspection criteria begins automatically. The inspector no longer needs to consult the complete set of weld inspection standards manually — the software ensures they are applied correctly.

Objective evaluation

Objective evaluation

Weld defect or within tolerance? The Weld Check app delivers reliable inspection results — with no room for interpretation — using a standardized testing process. A simple traffic light system clearly shows at a glance whether all required inspection criteria have been met.

Audit-ready results

Audit-ready results

All measuring data and results, including a target-actual comparison, are stored in the software. The test reports contain all relevant information (component, seam type, inspector, result, image documentation). That way, you can always track exactly what was tested. This creates security – for you and your customers.

All in one software

All-in-one software

Weld Check is an app within the metrology software ZEISS INSPECT, which already includes functions for presence analysis as well as GD&T inspections of welded constructions according to DIN EN ISO 13920. In combination with Weld Check, inspectors get a comprehensive tool that supports all areas of inspection. The results can be combined and presented in a single report.

Everything you need, all integrated:

With Weld Check, you can reliably detect and evaluate weld imperfections according to DIN EN ISO 5817.

Selected examples:

  • 503: Excessive Weld Reinforcement (Fillet Weld)

    Excessive Weld Reinforcement refers to a fillet weld where the weld throat or leg length significantly exceeds the required size, potentially leading to stress concentrations or reduced fatigue resistance.

    Weld Check provides the inspector with a clear quality assessment. In this example, the measured fillet weld exceeds the target value but remains within the acceptable tolerance range.

  • 505: Abrupt Weld Transition

    Abrupt Weld Transition refers to a sharp or uneven change between the weld and the base material, instead of a smooth, gradual blend. This can lead to stress concentrations and negatively affect the fatigue strength of the joint.

    This weld shows an abrupt transition to the base material. Weld Check flags the sharp edge as non-compliant – rework on the part is necessary.

  • 512: Excessive Asymmetry of Fillet Weld

    Excessive Asymmetry of Fillet Weld refers to a fillet weld where the two leg lengths differ significantly. This can compromise load distribution and reduce the structural integrity of the joint.

    Weld Check analyzes three measurement values to detect a potential asymmetry of the fillet weld. In this case, the software indicates that the measured feature is within tolerance.

  • 5052: Weld Transition Radius

    The Weld Transition Radius is a critical parameter for calculating the fatigue life of a component. However, it is challenging to capture accurately using traditional measurement tools such as calipers. As a result, this inspection characteristic is often ignored or omitted.

    Weld Check now enables inspectors to evaluate this feature with the highest precision – delivering real added value for you and your customers.

  • 5213: Undersized Fillet Weld

    Undersized Fillet Weld means that the actual throat thickness falls short of the required target value defined in the technical drawing. Weld Check shows that the measured fillet weld is smaller than specified in the standard. The undersized geometry is flagged as non-compliant.

Weld Inspection

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