Custom NDT Solutions for Wheel Rail Interface Testing

When the public watches a train go by, they tend to watch the cars. But people in the industry know that the real action is in the wheels. The wheel rail interface is the most important component of a train’s operation, and it has to run smoothly to guarantee safety and efficiency. 

The enormous pressure that the wheels are constantly under means that wheels are ripe for encountering flaws. Their thickness must be inspected routinely to make sure that the wheel can withstand the stress. But every time a wheelset is taken off a train it increases downtime. 

That’s why custom nondestructive testing (NDT) solutions for wheel rail interfaces are so important. These inspections can be done with either ultrasonic or eddy current testing methods, both of which minimize downtime. Making sure the wheel rail interface is functioning at its highest level increases efficiency, protects property, and can even save lives. 

The Need for Wheel Rail Interface Testing

Nondestructive testing for the railway industry looks at several different components, including the strength of the rail itself. The rails are under a lot of pressure from the weight, strength, and speed of the train, and all of that is centered on the wheels. 

The flange on the wheel is critical for keeping it on the rail. Flanges have to maintain a thickness level that also helps prevent cracks and chips that can turn into huge problems. When the thickness thins, damage can occur. Nondestructive testing has to measure both thickness and inspect for minute flaws on all the irregular surfaces of the wheel. 

The thickness is also important for dissipating the heat as the train runs. The friction generates enormous amounts of heat, which can warp the rails and wreak havoc in the structure of the wheels, not to mention raising the heat on the train (which can be bad for specific freight). 

Regular inspections are vital and unavoidable (and indeed highly regulated). But the number of required inspections increases downtime. The key is to find NDT solutions that limit that downtime while maintaining the highest standards of efficacy and accuracy. 

The Benefits of Custom NDT Solutions for Wheel Rail Interface Testing 

The wheels on trains are bulky. They can be shaped irregularly. Modern trains can exist in complicated electromagnetic environments. An NDT solution has to be customized for the specific job in order to maximize its functionality. 

There are two primary types of NDT solutions for the wheel rail interface. Each of these solutions has different combinations of instruments, probes, scanners, and software. Finding the ones that are right for you are crucial to successful wheel rail interface testing. 

Ultrasonic Testing

Phased array ultrasonic testing (PAUT) equipment is an ideal solution for the challenges of wheel rail interface volumetric inspections due to its portability, affordability, and accuracy. When time is of the essence—as it often is—PAUT testing equipment does the job. 

Though there are many different kinds, with different degrees of sophistication for different jobs, advanced PAUT testing equipment offers significant benefits:

• 2D Array focus technology
• No need for interval or reverse detection 
• High performance
• Rugged
• Portable

Portability is hugely important for wheel rail interface testing, especially in crowded trainyards or large lots. Being able to keep moving with equipment, to test quickly as wheels come on and off, can greatly limit downtime and increase efficiency. 

Eddy Current Testing

For surface and subsurface flaw detection, eddy current testing tools are perfect for the unusual conditions of the railyard or shop. Handheld eddy current testing devices are ergonomic, rugged, and have a long battery life that lets technicians quickly inspect multiple wheelsets. 

Another benefit of eddy current testing is that the work can be done quickly, with remote data acquisition units. The ability to have fully automatic positioning and retracting makes for a much smoother process. 

Additionally, a highly flexible eddy current array probe is extremely easy to use, and requires no interval or reverse detection. All you have to do is start from the front or the rear of the wheel, and make one pass. This simplifies and improves the efficiency of the entire system. 

Finding the NDT Solution That’s Right For You

When determining which NDT solution for wheel rail interface testing is right for your needs, consider this: With the proper equipment, the detection time for a single wheel set can be under 60 seconds—that’s less than a minute to obtain a 2D or 3D rendering of thickness and defects, and enough time to make repairs without much downtime. 

Not only that, but many advanced systems use data mining techniques to enable an educated estimation of flaws. The accumulated information helps technicians understand what needs to be repaired right away and what can be scheduled, allowing for a smarter use of resources. 

Custom NDT solutions for wheel rail interface testing provides many benefits. These include:

• Precise detection
• High efficiency
• Excellent stability
• Time and labor saving
• Strong adaptability
• Intelligent choice making

Wheel rail interfaces are under a lot of pressure. But with the right custom NDT wheel rail interface testing solution, the technicians tasked with keeping them running don’t have to be. 

Check out this video to see how one high-speed railway technology company used the Zetec Dynaray high performance phased array UT instrument for detecting wheel defects without removing sanding pipes, cowcatchers, and other vehicle components.

Zetec is a major provider of nondestructive testing solutions for wheel rail interface testing. Contact us today to get the best equipment and the top solutions to keep your wheels rolling.