Ultrasonic is a popular nondestructive testing technique for detecting flaws in metals, composites and other materials. A major limitation of this technique for successful field implementation is the need for skilled labor to identify an appropriate testing methodology and conduct the inspection. A knowledge-based assistant that can help the inspector in choosing the suitable testing methodology would greatly reduce the cost for inspection while maintaining reliability. Therefore a rule-based decision logic that can incorporate the expertise of a skilled operator for choosing a suitable ultrasonic configuration and testing procedure for a given application is explored and reported in this paper. A personal computer (PC) based expert system shell, VP Expert, is used to encode the rules and assemble the knowledge to address the different methods in ultrasonic inspection for metals. The expert system will be configured in a question-answer format. Since several factors (such as frequency, couplant, sensors, etc.) influence the inspection, appropriate decisions have to be made about each factor depending on the type of inspection method and the intended use of the metal. This knowledge base will help in identifying the methodology for detecting flaws, cracks, and thickness measurements, etc., which will lead to increase safety.