One of the most commonly used optical methods for defect detection is radiographic inspection. Compared with methods that extract defects directly from the radiography image, model-based methods deal with the case of an object with complex structure well. However, detection of small low-contrast defects in nonuniformly illuminated images is still a major challenge for them. In this paper, we present a new method based on the grayscale arranging pairs (GAP) feature to detect casting defects in radiography images automatically. First, a model is built using pixel pairs with a stable intensity relationship based on the GAP feature from previously acquired images. Second, defects can be extracted by comparing the difference of intensity-difference signs between the input image and the model statistically. The robustness of the proposed method to noise and illumination variations has been verified on casting radioscopic images with defects. The experimental results showed that the average computation time of the proposed method in the testing stage is 28 ms per image on a computer with a Pentium Core 2 Duo 3.00 GHz processor. For the comparison, we also evaluated the performance of the proposed method as well as that of the mixture-of-Gaussian-based and crossing line profile methods. The proposed method achieved 2.7% and 2.0% false negative rates in the noise and illumination variation experiments, respectively.
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