Acoustic Emission Testing
operational data, AT allows engineers to build an evidence-based view of how components degrade over time. This supports condition-based maintenance, enabling inspection intervals to be shortened or extended based on actual equipment status rather than fixed cycles. When anomalies such as sudden changes in acoustic signal patterns are detected, engineers can interpret these with intelligent, AI-supported software tools. Depending on severity and localisation, decisions are made to either repair the defect, monitor it further, or plan replacement. All actions are documented and must be reviewed with inspection institutions, such as TÜV SÜD, to ensure compliance with national and international inspection standards.
Enhancing integration and reducing strain One of the strongest features of AT is its compatibility with other non-destructive testing methods. It can complement radiographic or ultrasonic inspections and, because of its livemonitoring capability, guide the timing and scope of these supplementary methods. Rather than inspecting every weld or tube, operators can use AT data to focus on areas showing acoustic anomalies— saving time and inspection effort. Moreover, AT can be performed using the present fluid, eliminating the need for drying processes and preventing issues like residual moisture-induced corrosion and contamination.
Conclusion Acoustic Emission Testing represents a pivotal advancement in industrial inspection. By combining real-time data collection with noninvasive procedures, it delivers a holistic view of equipment health while reducing costs and downtime. Its application is particularly beneficial in stainless steel and heat exchanger systems, where early damage detection, protective layer preservation, and inspection flexibility are essential. With proven success in operational environments and compliance with regulatory frameworks, AT offers a practical path forward for industries seeking more efficient ways to manage asset integrity.
About the authors
Rainer Semmler is the Head of Process Safety Management at TÜV SÜD Industrie Service, a branch of TÜV SÜD specialised in the inspection and testing of plants, infrastructure facilities and buildings. With a degree in process engineering, Semmler has worked in the process industry since 1991 and was declared an expert according to Section 29 a / b of the German Federal Immission Control Act in 1998. He has been with TÜV SÜD since 2011. Hermann Schubert is Head of Digital and Continuous Inspection at TÜV SÜD Industrie Service. With a degree in metallurgical engineering, Schubert specialised in damage mechanisms and advanced non-destructive testing( NDT). Certified Level 3 in Acoustic Emission and Ultrasonic Testing, Schubert has been instrumental in developing smart inspection solutions and asset health monitoring strategies. He joined TÜV SÜD in 2020.