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Die zerstörungsfreien Methoden zur Untersuchung und Charakterisierung von Materialien sowie zur Detektion von betriebsbedingten und herstellungsbedingten Fehlern mit akustischen und elektrischen Methoden werden vorgestellt. Schwerpunkt bilden die Ultraschall-, die Wirbelstrom- und die Streuflussprüfung. Die Verfahren werden anhand des Aufgabenspektrums des Fachbereiches 8.4 der BAM dargestellt.
Increased speed, heavier loads, altered material and modern drive system concepts result in an increasing number of flaws in railways. Caused by the rapid change in damage mechanism by modern rolling stock the appearance of the flaws also alters. Hence, interpretation of non-destructive rail testing results may become difficult. Caused by the changed interplay between detection method and flaw the recorded signals will result in an unknown type for the rail flaws type classification.
Methods for automatic rail inspection according to defect detection and classification have been developed continuously. Signal processing is a key technology to master the challenge of classification and maintain resolution and detection quality independently of operation speed.
The basic ideas of signal processing based on the Glassy-Rail-Diagram for classification purposes will be presented. Examples for the detection of damages caused by rolling contact fatigue are given. Synergetic effects of combined evaluation of diverse inspection methods are shown.
Non-destructive testing for surface crack detection and head check depth quantification at the gauge corner of railway tracks can be achieved using eddy current methods. With the extension of the tested zone to the running surface, rail defect signal types other than head checks can be measured. Due to their mostly irregular shape, a quantitation based on a calibration against regular test cracks of varying depth may not be linear. Estimates of the expected influence of more complex crack patterns may be obtained by a finite element simulation of sufficiently simple limiting cases, like two displaced or intersecting cracks or a simply branched or flexed crack. As a first step, a 3D finite element model of the HC10 eddy current probe distributed by Prüftechnik Linke und Rühe (PLR), Germany was built and verified against measured results from an (easily fabricated) reference block with isolated long cracks.