Phased array ultrasonic technique speeds up

examination of aluminothermic rail welds

Case Study

RAILECT system inspecting AT weld

A 1.2 million, European funded project managed by TWI Ltd has developed, produced and
demonstrated a novel clamp on prototype device for swift inspection of aluminothermic (AT) welds
in rail track. With 1.5 million AT welds in the UK alone and a further 65,000 welds being added
annually, the RAILECT consortium responded to the need to develop inspection approaches that
can confirm the structure of a joint with minimal track possession time.
The new semi-automated technology is able to provide a full volumetric inspection in 15 minutes,
saving both time and resources. The system works through the application of newly developed
phased array probes that are able to detect any faults within the AT weld. The system can be used
to identify and prevent breakages and is able to provide a better analysis of welds when compared
to the previous method of visual inspection.
Although the use of AT welds is well established, they are nevertheless critical safety components
in the European rail infrastructure; an increase of rail speed, density of rail traffic and greater
freight or passenger train weight can cause an increasing number of rail breaks across the
European rail network. The types of defects that are found in AT welds are those normally
associated with gravity feed castings, shrinkage, hot tears, lack of fusion and porosity. The main
two types of weld failure is a vertical fracture associated with centre-line shrinkage and split-web
fracture resulting from the cyclic nature of stress in the rail web on bends in the track. Adopting
inspection techniques that assure the track owner that no damaging defects are present is
essential. The system developed by the RAILECT team offers new confidence and efficiency to an
advancing European industry sector.
Following completion of this research project for the benefit of SMEs, the Railect device was
patented, and an agreement made for further development. TWI has invested over 100,000 in
developing the system further. This latest development has been to make the single system
adaptable to a wider range of rail profiles and includes increasing its robustness and its ability to
function in adverse weather. The potential exists for a traffic light inspection feature if acceptance
criteria are defined. Currently the system is being offered for trials to the European rail industry.
If adopted by the railway industry, the system would be one of the first systems of inspection
allowing rapid and simple detection of defects in rail welds. While enhancing rail safety significantly
it will also help rail operators reduce repair costs.
For more information please visit the RAILECT website or contact us.
The RAILECT project and website is managed by TWI and has received funding from the European
Community's Seventh Framework Programme managed byREA-Research Executive Agency (FP7SME-2008-2) under grant agreement no. 243791. Information is provided as is and no guarantee
or warranty is given that the information is fit for any particular purpose. The user thereof uses the
information at its sole risk and liability.

http://www.twi-global.com/news-events/case-studies/phased-array-ultrasonicaluminothermic-rail-welds-532/