Identifying Internal Rail

Defects with Non Destructive

Methods
1. Basic Testing Methods and Principles with
obstacles during Rail Testing.
2. Defect Type and Orientation
3. Technologies advancements.
4. Frequencies / Planning of testing.

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Ultrasonic Testing

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Testing Methods and Principles.

Current testing methods today that are used

to conduct non destructive inspection of
rail for internal flaws:
1. Ultrasonic.
2. Induction.
3. Vision.

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 Ultrasonic Testing
Terminology
1. Indication – any response.
2. Discontinuity – An unexpected response in the
rail that may be intentional or unintentional.
3. Reflector – Response to a surface that is
perpendicular to the angle of the ultrasonic
signal
4. Flaw – An imperfection that may be acceptable or
not acceptable.
5. Defect – A discontinuity that is not acceptable.

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 Testing Methods and Principles.
Ultrasonic testing
Ultrasonic sound is created when an electric current
causes a piezoelectric crystal to transmit a high
frequency vibration (sound wave).
Ultrasonic sound is a high frequency sound wave.
Testing sound frequency is between 2.5 MHz to
5 MHz.
Sound reflects when it strikes and acoustic
interface boundary. Different material velocities
or simply a defect or grain boundary.

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 Testing Methods and Principles.

Ultrasonic testing
- Couplant (water) is required to carry sound waves.
- Know angles used for typical defect detection
based on experience.
70 degree, 37.5 degree, and 0 degree transducers are
commonly used.
- Speeds are usually below 25 mph.
- Roller Search Units are used in North America
Transducers are inside a wheel filled with fluid.

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Ultrasonic Testing
70°
Transducers
45°
Transducers
0°
Transducers
Side looking
Transducers

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 Testing Methods and Principles

Ultrasonic testing
Disadvantages or shortcomings of Ultrasonic Testing
1. Rail Surface issues or irregularities
2. Speed or return of the Signal
3. Weather and contaminates
4. Area of coverage (base of rail and weld collars)

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 Testing Methods and Principles.
Currently all the North American suppliers use some form
of a B-Scan image. This simplifies the information by
organizing the data into an easily read presentation.

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 Testing Methods and
Principles
Vision
1. When and ultrasonic indication is present meeting
a specific criteria, a vision photo taken of that
location.

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Vision

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 Testing Methods and Principles

Disadvantages or shortcomings of Vision

1. Weather dependent
2. Only take photo when alarmed
3. Operator dependent
4. Large file sizes

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 Testing Methods and Principles
Induction
The introduction of electric current into a conductor
to create a magnetic field.
The main area of inspection is the head of the rail.
When the magnetic filed is disrupted or a flaw is
present, a change in the magnetic response is
noticed

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Induction Testing

TDD

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 Testing Methods and Principles

Disadvantages or shortcomings of Induction

1. Current limitation is that it only tests the head of
the rail
2. Does not test thru turnout and diamond areas
3. Area of coverage (web and base)

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 Testing Methods and Principles

Disadvantages or shortcomings of Induction

1. Current limitation is that it only tests the head of
the rail
2. Does not test thru turnout and diamond areas
3. Area of coverage (web and base)

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Rail Defects

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 Ultrasonic Testing
Rail Flaws (Defects)
1. Three type of flaws or discontinuities
• Inherent
• In‐service
• Process (Manufacturing)

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 Ultrasonic Testing
Rail Flaws (Defects)
1. Inherent
- This is from the materials or alloy material
• Discontinuities include some of the following items
inclusions, porosity, shrinkage and segregation.
• Note that inclusions can be non‐metallic and metallic.

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 Ultrasonic Testing
Rail Flaws (Defects)
In-service

Discontinuities that occur while rail is in revenue

service. There are many causes such as vibration,
heat, impact and other items.

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 Ultrasonic Testing
Rail Flaws (Defects)
Process (Manufacturing)
Primary Processing – This is the initial part of the rail
manufacturing and shaping of the rolling rail.
Secondary Processing – This is the final process to
finish the rail such as heat treating and machining.

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2222
RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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RAIL DEFECT REVIEW

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Testing Methods and Principles.
Currently in North American on most
Railroads use stop / start mode. However
there are 2 other concepts that are starting
to be explored.
1. Stop and Start Mode. (Commonly used in North
America)
2. Combo / Chase. (concept)
3. Non Stop. (widely used in Europe and being
introduced to North America)

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Testing Methods and Principles.
Stop and Start Mode
1. Test is conducted by an Operator who
interprets the indications from the test
systems.
2. Conducts hand tests to validate suspect
indications at time of test.

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Testing Methods and Principles.
Combo / Chase unit.
1. Lead unit tests the track and the Operator
identifies suspect indications that need to be
validated.
2. Information is sent to a chase car that is behind
the test car same day or sent to a Combo car to
verify the next day.

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Non Stop Testing
1. Test unit tests without
stopping.
2. The information is
then sent to a remote Transmits to be post processed
location and post
processed.
3. The suspect locations Suspect
indications
identified during sent for
processing are tested verification
by either a portable Report findings
hand test unit or a
chase truck with a
test system on board

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 Ultrasonic Testing
Frequency Planning
1. At CN, we developed a risk based model to
establish testing frequency that meet or exceed
FRA and TC minimum requirements.
*Some examples of risks considered would be rail
weight, ISRF, Defect history, and TQI.

2. Use rail testing historical average to develop car

count plan.
*Using the history of each subdivision and average
miles tested to forecast car counts.

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 Ultrasonic Testing
This chart
has been
scaled

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 Ultrasonic Testing
Where do we go from here ?
1. Eddy current – start to measure and better
understand RCF
2. Base defect detection.
3. Joint bar testing / defect detection.
4. Better modes of testing heavy haul main
corridors.
5. Laser induced ultra-sonics.

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