Porosity — Definition & NDT Use
The presence of gas voids or cavities in a weld or casting, appearing as rounded discontinuities. Porosity is caused by gas entrapment during solidification, improper shielding gas coverage (in welds), or excessive moisture in coatings. Scattered porosity of small size may be acceptable, but large or clustered porosity weakens material. Porosity is readily detected by radiography and ultrasonic testing.
In service, Porosity starts as a discontinuity that may or may not breach the acceptance criteria of the governing code; the NDT method's job is to detect it, characterise it, and size it so an engineer can decide whether to repair, monitor, or accept. Radiation passes through the part and a dense region (more material, more attenuation) records as a lighter band on film or digital detector, while a void, lack of fusion, or porosity records as a darker area; an image quality indicator (IQI) verifies that the technique was sensitive enough to be trusted. The fitness-for-service decision typically pairs the NDT call with material data and stress information; the inspector's job is to give the engineer a clean characterisation rather than to make the keep-or-reject call alone.
The decision tree around Porosity runs: detect, characterise, size, and refer to the acceptance table in the governing code; only the last step decides repair, accept-as-is, or fitness-for-service review. On welded fabrication it is most often paired with VT and one volumetric method (RT or UT) so surface and internal defects are both addressed.
- Etymology / Origin
- Latin porus (pore); used in metallurgy since the 19th century for gas voids trapped in solidifying metal.
- Formula
- Areal porosity = (sum of pore areas) / (evaluation area); often reported as % per AWS D1.1 Table 6.1.
- Units
- Pore size in mm; cluster area in mm^2; % areal coverage.
- Typical Range
- Detectable by RT down to ~0.5 mm pore in moderate sections; UT detects only when porosity is dense enough to attenuate or scatter measurably.
- Measured / Produced By
- RT/DR (best for porosity), VT (large surface-breaking pores), UT (indirect — scatter and attenuation), PAUT (cluster mapping).
- Code References
- AWS D1.1 Cl. 6.12 (visual + RT acceptance for porosity); ASME Section IX Cl. QW-191 (radiographic acceptance); API 1104 Sec. 9 (girth weld porosity)
- Worked Example
- Cluster of six 1 mm pores within a 25 mm length on a fillet weld: AWS D1.1 statically-loaded acceptance allows up to 9.5 mm pore in a 19 mm weld — cluster passes if no individual pore exceeds the limit.
AWS D1.1
Structural Welding Code — Steel; defines visual and NDE acceptance for static and dynamically loaded welds.
ASME Section IX
Welding, brazing, and fusing qualifications referenced by every U.S. pressure-equipment code.
ASME Section V Article 4
Ultrasonic examination methods for welds and components.
ASTM E114 / E164 / E2375
ASTM straight-beam, contact, and wrought-product UT practices.
Confusing porosity with a generic "indication" is a recurring error; the term carries an engineering implication, and the report should distinguish the discontinuity (what was seen) from the disposition (what code says about it).
What does "Porosity" mean in NDT?
The presence of gas voids or cavities in a weld or casting, appearing as rounded discontinuities. Porosity is caused by gas entrapment during solidification, improper shielding gas coverage (in welds), or excessive moisture in coatings
Is porosity always rejectable?
No. Whether a porosity indication is rejectable depends on the acceptance criteria of the governing code (AWS D1.1, ASME Section VIII, API 1104, etc.), the size and orientation of the indication, and any fitness-for-service evaluation the engineer chooses to apply.
What other NDT concepts should I read alongside Porosity?
The most directly related entries in this glossary are "void", "cavity", "gas pocket"; reading those together gives you the surrounding vocabulary used in inspection reports and procedures.
