Automated Ultrasound-Based Inspection of Rails: Review
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IJR International Journal of Railway The Korean Society for Railway Vol. 10, No. 2 / December 2017, pp. 21-29 Automated Ultrasound-based Inspection of Rails: Review Suvi Santa-aho†, Antti Nurmikolu, and Minnamari Vippola Abstract The main aim of the report is to review recent progress in the utilisation of ultrasound-based automated inspection sys- tems for rails of railway tracks and to provide a basis for further research in the field of railway track inspection. This paper reviews the ultrasound technologies currently employed in the automated inspection of railway tracks, along with examples of recent field applications. The main research areas that this review focuses on are firstly, the utilisation of ultrasound inspection for rail tracks; secondly, the different automated ultrasound techniques, and, finally, the special fea- tures of the ultrasound inspection of railway tracks. In addition, there is a review of the most recent ultrasound-based systems, and future techniques that have not yet been automated or used in routine inspection. Keywords: Automated inspection, Ultrasound, Track inspection, Nondestructive testing 1. Introduction may incorporate many inspection methods, i.e. ultrasonic testing facilities [3], the induction method [3], (pulsed) Non-destructive testing (NDT) or non-destructive evalu- eddy current testing [2,5,6] and/or image processing tech- ation (NDE) is characterised as the examination of an nology for visual testing of sectional wear measurement, object without affecting the future usefulness of the and rail corrugation measurement using lasers [2]. The tar- inspected component [1]. The inspection of railway tracks get of one example project was to develop a measurement is important in order to find defects before they reach criti- system combining ultrasound, alternating current field cal size and cause failure in the railway track structure [2]. measurement (ACFM) and artificial vision [7]. Inspection The trend is to combine the NDT of the railway track with systems can be integrated with grinding test trains [5]. In preventative maintenance procedures (like rail head grind- addition, the trend in rail flaw detection is towards improv- ing) to optimise the compromise between maintenance ing the efficiency of measurements whilst minimising cost and reliability [2]. track time for maintenance, as Clark [3] suggests. Auto- Many different NDT methods are utilised for railway matic inspection systems that are able to detect rail defects track condition monitoring. Contact ultrasonic testing will increase the ability of inspection and reduce the mea- belongs to the first methods utilised for railway tracks surement time, allowing more accurate and frequent main- along with magnetic induction method [3]. Nowadays and tenance work [8]. probably even more so in the future, railway track NDT is Various mechanisms are responsible for the different being combined with measurement systems consisting of defect types that appear in rails of railway tracks. many different methods, completing the information Commonly, ultrasound inspection is used for finding gained about the defects and increasing the probability of internal defects that are formed during the cyclic load- defect detection [4]. At present, rail inspection vehicles ing of rails [4]. Ultrasound inspection is capable of searching for the inner defects that lie under the sur- face. The inspection uses a beam of ultrasonic energy † Corresponding author: Tampere University of Technology, Department of Materi- that penetrates the inspected component via a probe als Science, Tampere, Finland and a couplant in between. Ultrasound energy is E-mail : [email protected] reflected back or scattered from boundaries with differ- ⓒThe Korean Society for Railway 2017 ent acoustic emissions. The received signals are col- http://dx.doi.org/10.7782/IJR.2017.10.2.021 Vol. 10, No. 2 / December 2017 − 21 − Suvi Santa-aho, Antti Nurmikolu, and Minnamari Vippola / IJR, 10(2), 21-29, 2017 lected with receiver transducers and studied in order to 2. Basic Principle of Ultrasound find possible defects [9]. Measurements for Railway Tracks The cyclic loading of rails causes wear and wear- related changes and therefore the rails are inspected Ultrasound inspection is based on sound waves, or periodically to ensure that no possible flaws and defects vibrations, created by a piezoelectric crystal in the probe, compromise the traffic. Certain regulations for track that propagate in solids, liquids and gases, at a frequency maintenance exist and, for example, in the United above the range of human hearing, normally above 20 States, inspection for rail flaws is carried out at inter- kHz. Sound waves can propagate in different forms, of vals based on the track class and annual tonnage [10]. which the most generally used in inspections are longitudi- Ultrasound inspection for rails of railway tracks can be nal (compression) or transverse (shear) waves. The differ- carried out manually with hand-held devices or with fix- ence between these waves is the particle motion in relation tures moved by an operator that slide on top of the rail, to the sound wave direction [9]. In addition, surface waves or with automated ultrasound test fixtures towed by hi- and Lamb waves can be used in some special cases in the rail inspection vehicles or inspection trains. Some rail- inspection of thin structures. Sound waves travel with dif- way track inspection techniques can be installed on ferent velocity depending on the material. The factors commercial trains, but at the current state of inspection affecting this are density and the elasticity of the material. method development, ultrasound inspection is still In addition, different waveforms have different speeds in unsuitable for commercial trains [11]. the material; a transverse wave travels at almost half of the The German Institute for Standardization (DIN) has speed compared to a longitudinal wave [9]. Different recently published a draft standard “DIN EN 16729-1 materials have different acoustic impedance values, mean- Railway Applications - Infrastructure - NDT On Rails In ing that the ultrasound energy is refracted from the bound- Track - Part 1: Requirements For Ultrasonic Inspection ary between different media [9]. The discontinuities act as And Evaluation Principles” of ultrasonic inspection for a reflector to the ultrasonic waves, resulting in a portion of railways [12]. The draft specifies reference reflectors on the wave being reflected back to the receiver. These the test track for ultrasound inspection to produce compa- echoes are studied in order to find defects. In cases when rable results with regard to location, type and size of refer- there are no other reflectors, the reflection comes back to ence reflectors. the receiver from the back wall of the inspected compo- This paper reviews the technologies currently employed nent. If the back wall echo is missing, it might be caused along with examples of recent field applications. The main by defects masking it and in this case also there might be a aim of this report is to review the recent progress in the potential defect in the structure [13]. utilisation of automated techniques and to provide a basis The most common method for ultrasound inspection is for further research. The concept of the ultrasound inspec- called the pulse-echo method. The same transducer sends tion method for railway tracks will be presented in Sec- and receives the pulses which are studied; for example the tion 2, the ultrasound equipment and units for automated amplitude and the time that the ultrasound beams travels inspection in Section 3, rail defects and the probability of inside the inspected component. There exist different their detection and special features of the ultrasound probe configurations for the measurements. A normal inspection of railway tracks in Section 4, future inspection beam probe transmits ultrasound wave that is directed systems for railway track inspection in Section 5 and other straight to the face of the transducer. Probes can be aligned ultrasound-based inspection systems for railway track with wedges in different angles as a function of the inspection in Section 6. Conclusions are presented in Sec- inspected component surface. These probes are called tion 7. This review was carried out in liaison with the Life angle probes [1,9,14]. Cycle Cost Efficient Track research programme (TERA) Generally, NDT techniques are used to locate flaws, to implemented in co-operation with the Finnish Transport size them and to characterise material conditions. A basic Agency and Tampere University of Technology (Finland). flaw detection procedure is applied: firstly, the defects The research programme comprises ten sub-areas, one of need to be detected, secondly, the dimensions can be deter- which is research on track rail life cycle. At the moment, mined and, finally, the evaluation of the defects based on research activity on rails is concentrated on the verifica- the acceptance criteria must be performed. Usually, the tion of rolling contact fatigue and surface defects in Finn- ultrasound systems use a threshold level in a gate to record ish rails, as well as suitable analysis methods for rail the ultrasound response in cases where the reflection is inspection. above this level [12]. The preferred system for data presentation of ultrasound − 22 − Automated Ultrasound-based Inspection of Rails: Review inspection results, i.e. flaw indications, from rails has been probes can be either in direct contact to the surface [5] or the B-scan [3,15,16]. The B-scan based test system pro- there may be a belt between the probe and the vides an image of a defect in the perpendicular direction of surface [21]. The belt system protects the probe unit from the rail. It gives the cross-sectional display of the time-of- mechanical shocks and against damage caused by bad flight data from the surface of the rail to the bottom of the track conditions [21]. In the studies made by Heckel et rail [9]. Heckel et al. [5] reported the use of a Glassy-Rail- al.