Development of phased array ultrasonic system for detecting rail cracks

• Published in: Sensors and actuators. A. Physical. Vol. 311; p. 112086
• Main Authors: Kim, Geonwoo, Seo, Mu-Kyung, Kim, Yong-Il, Kwon, Segon, Kim, Ki-Bok
• Format: Journal Article
• Language: English
• Published: Lausanne Elsevier B.V 15.08.2020; Elsevier BV
• Subjects: CIVA software; Cracks; Defects; Design factors; Non-destructive testing (NDT); Nondestructive testing; Performance tests; Phased array ultrasonic testing (PAUT); Phased arrays; Radiographic testing; Radiographic testing (RT); Radiography; Rail; S-scan; Simulation; Software; Transducers; Ultrasonic technology; Ultrasonic testing; Verification; Water tanks; Weld defects; Welding; Radiographic testing (RT); Non-destructive testing (NDT); CIVA software; Rail; S-scan; Phased array ultrasonic testing (PAUT)
• ISSN: 0924-4247; 1873-3069
• DOI: 10.1016/j.sna.2020.112086

[Display omitted] •Two 2.25 MHz ultrasonic transducers.•Acoustic field analysis.•Defect detection simulation by CIVA software.•Artificial and natural defect detection.•Comparison with radiographic testing. In this study, a phased array ultrasonic system for detecting rail cracks (PAUSR) was developed which consists of two phased array (PA) ultrasonic transducers, a water tank, a display monitor, a battery, a commercial 64 channel PA board, and its control software. To accomplish this, the acoustic fields and crack detection images of newly developed PA ultrasonic transducers were simulated and analyzed by the CIVA (CIVA 2016, NDE CIVA, USA) software. The major design factors for the PAUSR is the capability of evaluating crack size (over 2 mm), generating proper acoustic fields in the rail and easy and safe handling for operators. For the performance test of the designed PA ultrasonic transducer, Non-destructive Characterization and Verification of Ultrasonic Phased Array Equipment, Part 2: Probes (EN ISO 18563-2:2017) was conducted. In addition, artificial crack detection images were simulated by the CIVA software, and an experiment under the same CIVA simulation conditions was also performed for comparison purposes. For the last verification, natural defective specimens with bolt-hole star-cracking, longitudinal vertical cracking and welding defects were scanned by the developed PAUSR, and its results were analyzed and compared with the radiographic testing (RT) and CIVA simulation outcomes.