For aerospace manufacturers and suppliers, non-destructive testing (NDT) is a mandatory requirement for airworthiness, regulatory approval, and OEM supplier qualification.
Modern aircraft are built from highly engineered materials and complex structures. Even the smallest imperfection can impact safety or performance.
Aerospace NDT allows critical parts to be inspected thoroughly — without causing damage — throughout production, assembly, and maintenance.
It supports manufacturers and MRO providers by:
Early defect detection
Identifying internal and surface flaws at an early stage, reducing safety risks, rework, and unplanned failures.
Regulatory compliance
Providing documented evidence required for aviation authority approvals and OEM audits.
Airworthiness assurance
Maintaining consistent quality, reliability, and operational safety throughout the component lifecycle.
When aerospace components are involved, testing must be precise, controlled, and trusted worldwide. TÜV SÜD delivers aerospace NDT through Bytest, its own fully owned and operated testing laboratory in Italy, ensuring consistent quality, accountability, and global acceptance.
Ultrasonic Testing uses high-frequency sound waves to detect internal defects and verify material integrity without damaging components.
Applicable components
Our ultrasonic testing services
TÜV SÜD provides ultrasonic testing through Bytest, using immersion, contact, and squirter techniques. Testing is performed by certified aerospace NDT personnel in accordance with EN 4179, NAS 410, and EN ISO 9712.
Key characteristics
Radiographic Testing and Computed Tomography examine the internal structure of components using X-ray or gamma radiation, enabling inspection and measurement without damaging the part.
Applicable components
Our radiographic and CT services
Chemical analysis is used to determine the chemical composition and selected physical properties of materials used in aerospace and other safety-critical applications.
Our chemical analysis services
Liquid Penetrant Testing is used to detect surface-breaking defects in non-porous materials, including cracks, laps, porosity, and micro-shrinkage.
Applicable components
Our liquid penetrant testing services
TÜV SÜD provides liquid penetrant testing through Bytest, using fluorescent penetrant inspection systems with post-emulsifiable hydrophilic and water-washable processes. Inspections are performed in controlled laboratory conditions and are suitable for both small parts and large, complex components.
Testing is performed in accordance with ASTM E1444, ASTM E165, ASME Section V, Article 6, and AMS 2645, and is subject to regular process control and maintenance checks.
Bytest is NADCAP accredited for the PT method.
Failure Analysis is an engineering investigation used to identify the root cause of breakage, damage, or malfunction in components and products used in aerospace and other safety-critical applications.
Scope of investigation
Failure analysis may address issues arising from:
Our failure analysis services
TÜV SÜD performs failure analysis through Bytest, applying a structured and impartial approach based on engineering expertise and technical evidence. Investigations are carried out by experienced specialists with extensive background in damage mechanisms and materials behaviour.
Investigation process
Magnetic Particle Testing is used to detect surface and near-surface discontinuities such as cracks, inclusions, laps, and micro-shrinkages in ferromagnetic components.
Applicable components
Our magnetic particle testing services
TÜV SÜD provides magnetic particle testing through Bytest, using continuous wet techniques with fluorescent particles and colour contrast methods. Testing is performed using controlled magnetisation systems suitable for a wide range of component sizes and geometries.
Testing is performed in accordance with ASTM E1444, ASTM E709, ASME Section V, Article 7, and EN ISO 9934 (Parts 1–3).
Bytest is NADCAP accredited for the MT method.
Materials testing is used to verify the mechanical, chemical, and metallurgical properties of materials in accordance with industrial and aerospace requirements.
Our materials testing services
Bytest performs materials testing covering:
Materials testing is performed in accordance with relevant industrial and aerospace standards.
The laboratory holds NADCAP and ACCREDIA accreditations for a wide range of materials testing activities.
Mechanical testing of materials
The Bytest materials testing laboratory carries out destructive mechanical tests to determine material behaviour under defined loading conditions.
Testing includes:
Metallographic analysis is used to assess the microstructural quality and suitability of materials for their intended application, in accordance with recognised standards and customer specifications.
Our metallographic analysis services
The Bytest Metallographic Laboratory performs a wide range of destructive examinations, including:
Metallographic testing is performed in accordance with applicable reference standards and customer requirements.
The laboratory is accredited by NADCAP (Materials Testing Laboratory) and ACCREDIA.
Yes. Inspection results issued by TÜV SÜD through Bytest are accepted by aviation authorities and leading aerospace manufacturers. Testing is performed within accredited and audited quality systems, and Bytest holds customer-specific approvals from OEMs such as Leonardo, Rolls-Royce, GE Avio, and Safran, supporting supplier qualification and programme approvals.
Yes. Documented and standard-compliant NDT is mandatory for airworthiness approval, production release, and continued operation of aircraft and helicopter components, in accordance with regulatory and OEM requirements.
Aerospace NDT is performed in accordance with internationally recognised standards, including EN 4179, NAS 410, EN ISO 9712, and relevant ASTM and ASME standards. These frameworks define personnel qualification, inspection methods, and process control requirements.
Yes. Aerospace NDT activities performed by TÜV SÜD through Bytest are supported by engineers holding Level 3 NDT qualifications recognised by leading aerospace OEMs.
Examples include:
These Level 3 qualifications support method approval, technical oversight, and compliance with aerospace standards for non-destructive testing activities.
Aerospace non-destructive testing (NDT) refers to inspection methods used to evaluate aircraft, helicopter, and aerospace components without causing damage. These methods are essential for verifying structural integrity, detecting defects, and supporting airworthiness throughout production, maintenance, and overhaul.
Yes. In addition to laboratory testing, TÜV SÜD can perform selected aerospace NDT activities directly on site, depending on the inspection method, component size, and regulatory requirements.
The required NDT method depends on component design, material, applicable standards, and OEM or regulatory requirements. TÜV SÜD can support technical discussions to determine the appropriate inspection approach for each application.
Yes. Bytest operates a dedicated Research Center in Volpiano in collaboration with the University of Eastern Piedmont. Research focuses on advanced aerospace NDT technologies such as automated radiographic inspection, innovative materials, and robotic inspection systems.
Bytest actively contributes to European innovation programmes, including MIMOSA (Horizon Europe). These projects focus on advanced aircraft structures, such as hybrid metal-composite joints, and support the development of future certification and inspection frameworks.