A review of sensor-based non-destructive testing and evaluation techniques: Principles, applications, and smart systems

Published: 2026
Measurement vol. 282
ISBN/ISSN: 0263-2241

Abstract

Structural safety and operational reliability are essential across industries, as undetected defects can lead to severe failures and losses. Non-destructive testing (NDT) is essential for detecting and evaluating material integrity without damage. This paper reviews sensor-based non-destructive testing techniques that can be incorporated into a portable-sized system, serving as an introductory resource to the field. It presents the abilities, limitations, operational principles, and applications of ultrasonic testing, acoustic emission, eddy current testing, infrared thermography, eddy current thermography, magnetic flux leakage, and radio-frequency identification. The review also presents the Non-Destructive Evaluation concept and differentiates it from NDT by focusing on the quantitative assessment of defect characteristics, material quality, and relevance to structural integrity.

The primary purpose is to explore technological advancements and the integration of these techniques into intelligent frameworks for easier testing and real-time monitoring. The key findings show that no single NDT method addresses all inspection requirements, leading to the need for hybrid NDT approaches that integrate complementary techniques to improve defect coverage and reliability. The importance of AI is also highlighted for automating defect classification, analysis, and measurement across all NDT modalities, significantly enhancing accuracy and reducing human-dependent errors. Another objective is the exploration of smart NDT systems achieved through the integration of NDT sensor technology with embedded systems and Internet-of-Things features for real-time monitoring and automation.

In conclusion, this review aims to guide researchers and engineers in understanding both established NDT methods and the technological shifts that enable smart, hybrid, and AI-supported inspection systems. By connecting conventional practice with emerging trends, it encourages the adoption of NDT within smart platforms and supports innovation in next-generation evaluation and monitoring systems.