On monitoring fretting fatigue damage in solid railway axles by acoustic emission with unsupervised machine learning and comparison to non-destructive testing techniques

Railway axles are safety-critical components of the rolling stock and the consequences of possible in-service failures can have dramatic effects. Although this element is traditionally designed against such failures, the initiation and propagation of service cracks are still occasionally observed, requiring an effective application of non-destructive testing and structural health monitoring approaches. This paper investigates the application of structural health monitoring by acoustic emission to the case of solid railway axles subject to fretting fatigue damage. A full-scale test was performed on a specimen in which artificial notches were suitably manufactured in order to cause the initiation and evolution of fretting fatigue damage up to the stage of relevant propagating fatigue cracks. During the test, both periodical phased array ultrasonic inspections and continuous acquisition of acoustic emission data have been carried out. Moreover, at the end of the test, the specimen was inspected, analyzed and evaluated by visual inspection and magnetic particles testing, while acoustic emission raw data were post-processed by a special unsupervised machine learning algorithm based on an Artificial Neural Network. It is demonstrated that the proposed methodology is very effective to detect the onset of crack initiation in a non-invasive and safe way

Rail Diagnostics Based on Ultrasonic Guided Waves: An Overview

Rail tracks undergo massive stresses that can affect their structural integrity and produce rail breakage. The last phenomenon represents a serious concern for railway management authorities, since it may cause derailments and, consequently, losses of rolling stock material and lives. Therefore, the activities of track maintenance and inspection are of paramount importance. In recent years, the use of various technologies for monitoring rails and the detection of their defects has been investigated; however, despite the important progresses in this field, substantial research efforts are still required to achieve higher scanning speeds and improve the reliability of diagnostic procedures. It is expected that, in the near future, an important role in track maintenance and inspection will be played by the ultrasonic guided wave technology. In this manuscript, its use in rail track monitoring is investigated in detail; moreover, both of the main strategies investigated in the technical literature are taken into consideration. The first strategy consists of the installation of the monitoring instrumentation on board a moving test vehicle that scans the track below while running. The second strategy, instead, is based on distributing the instrumentation throughout the entire rail network, so that continuous monitoring in quasi-real-time can be obtained. In our analysis of the proposed solutions, the prototypes and the employed methods are described

Review of Multiaxial Testing for Very High Cycle Fatigue: From ‘Conventional’ To Ultrasonic Machines

Fatigue is one of the main causes for in service failure of mechanical components and structures. With the development of new materials, such as high strength aluminium or titanium alloys with different microstructures from steels, materials no longer have a fatigue limit in the classical sense, where it was accepted that they would have ‘infinite life’ from 10 million (107) cycles. The emergence of new materials used in critical mechanical parts, including parts obtained from metal additive manufacturing (AM), the need for weight reduction and the ambition to travel greater distances in shorter periods of time, have brought many challenges to design engineers, since they demand predictability of material properties and that they are readily available. Most fatigue testing today still uses uniaxial loads. However, it is generally recognised that multiaxial stresses occur in many full-scale structures, being rare the occurrence of pure uniaxial stress states. By combining both Ultrasonic Fatigue Testing with multiaxial testing through Single-Input-Multiple-Output Modal Analysis, the high costs of both equipment and time to conduct experiments have seen a massive improvement. It is nowadays possible to test materials under multiaxial loading conditions and for very high number of cycles in a fraction of the time compared to non-ultrasonic fatigue testing methods (days compared to months or years). This work presents the current status of ultrasonic fatigue testing machines working at a frequency of 20 kHz to date, with emphasis on multiaxial fatigue and very high cycle fatigue. Special attention will be put into the performance of multiaxial fatigue tests of classical cylindrical specimens under tension/torsion and flat cruciform specimens under in-plane bi-axial testing using low cost piezoelectric transducers. Together with the description of the testing machines and associated instrumentation, some experimental results of fatigue tests are presented in order to demonstrate how ultrasonic fatigue testing can be used to determine the behaviour of a steel alloy from a railway wheel at very high cycle fatigue regime when subjected to multiaxial tension/torsion loadings

Review of Modern Nondestructive Testing Techniques for Civil Infrastructure

The repair and maintenance of aging infrastructures, in the United States alone, are estimated to have backlogs of trillions of dollars. This has posed widespread concerns about the existing and proposed infrastructures to adequately sustain the quality of life in the near future. Efficient and cost-effective approaches, such as nondestructive testing (NDT), are therefore required to better shape our future. Various NDT techniques have been developed over the past two decades with cutting-edge advances towards investigation and condition assessment of civil infrastructures. While the performance of NDT techniques has reached unparalleled heights, limitations remain. On one side, are the instrument limitations such as penetration depth, resolution, data analysis, accessibility, etc., that are being addressed by the constantly evolving field of NDT. On the other side, there are gaps in the validation and strategic standardization of the techniques for their application in the field. These gaps are further broadened by the lack of experience and understanding of the techniques by the officials with the authority of repairing and maintaining infrastructures, such as the federal and state Department of Transportation (DOT) personnel. This report aims to be a comprehensive review of state-of-the-art nondestructive testing techniques such as Impact-echo, Ultrasonic Testing, Infrared Thermography, and Digital Tap Hammer. Research and innovation integrated into contemporary features and possible future trends of such techniques for rapid and inclusive condition assessment of concrete and timber structural members are presented in the report. As the future of NDT, this report reviews the alignment of NDT techniques with novel automated technologies, including Unmanned Aerial System (UAS). Such practices have shown promising results in the effective and proactive condition assessment of structures with greater ease and at significantly lower cost, without the need for extensive knowledge about the techniques. Hence, it is recommended that the responsible bodies such as federal and state DOTs utilize nondestructive testing techniques to improve the resiliency and service life of our infrastructures effectively

Rail and wheel health management

Rail and wheel health management is investigated with focus on deterioration phenomena in the wheel/rail contact interface – plastic deformation, wear, and rolling contact fatigue (RCF). How operational conditions affect deterioration, and how they can be included in wheel/rail health predictions is linked to a more in-depth description of deterioration mechanisms. Here means of measuring, quantifying, and predicting deterioration is in focus. This discussion provides the basis for the outline of a rail and wheel health management framework. As discussed in the paper, the proposed framework is well in line with the requirements in the ISO 55000 standard for asset management

Novel Approaches for Structural Health Monitoring

The thirty-plus years of progress in the field of structural health monitoring (SHM) have left a paramount impact on our everyday lives. Be it for the monitoring of fixed- and rotary-wing aircrafts, for the preservation of the cultural and architectural heritage, or for the predictive maintenance of long-span bridges or wind farms, SHM has shaped the framework of many engineering fields. Given the current state of quantitative and principled methodologies, it is nowadays possible to rapidly and consistently evaluate the structural safety of industrial machines, modern concrete buildings, historical masonry complexes, etc., to test their capability and to serve their intended purpose. However, old unsolved problematics as well as new challenges exist. Furthermore, unprecedented conditions, such as stricter safety requirements and ageing civil infrastructure, pose new challenges for confrontation. Therefore, this Special Issue gathers the main contributions of academics and practitioners in civil, aerospace, and mechanical engineering to provide a common ground for structural health monitoring in dealing with old and new aspects of this ever-growing research field

A holistic approach to remote condition monitoring for the accurate evaluation of railway infrastructure and rolling stock

The rail industry needs to address a number of important operational challenges in the foreseeable future. First of all, the safety of rail transport needs to be maintained at an absolute maximum matching the achievements of the European airline industry of zero fatalities. Secondly, promote sustainable growth to support increasing demand for both passenger and freight rail transport. Thirdly, support the implementation of measurable innovations and improvements that help increase capacity of current infrastructure through enhanced availability. Finally, maximise the environmentally benign character of railway transport through exploitation of novel technologies such as hydrogen trains and advanced electrification employing renewable energy sources. This project, primarily focused on the UK Rail infrastructure, investigated the benefits arising from a holistic approach in the application of Remote Condition Monitoring (RCM) as a critical means for the accurate, efficient, reliable and cost-effective evaluation of key railway infrastructure assets and rolling stock. This work involved the use of several techniques and innovative methodologies based primarily on Acoustic Emission (AE) and vibration analysis in order to address the evaluation requirements for different components of interest. The results obtained have been very promising and present rail infrastructure managers and rolling stock operators with new opportunities for improved and more reliable operations. This work has led to the instrumentation of multiple sites across the UK rail network enabling measurements to be carried out on various assets under actual operational conditions. At Cropredy an integrated high-frequency vibro-acoustic RCM system has successfully been installed on the Chiltern railway line on the way from London to Birmingham. This customised system has been fully operational since 2015 measuring more than 200 passenger and freight trains every day moving at speeds up to 100 miles per hour (MPH). Prior to the installation of the system at Cropredy a Certificate (PA05/06524) of Acceptance was issued by Network Rail which after being renewed recently is now valid until September 2021. The system is due for an upgrade in the following stage of development, employing wireless sensors and advanced energy harvesting devices which are being developed under a collaborative Engineering and Physical Sciences Research Council (EPSRC) project between Exeter and Birmingham Universities, Network Rail, Swiss Approval UK and Quatrro. The widespread implementation of the techniques and methodologies researched will give rise to significant potential impact with respect to the effectiveness of maintenance strategies, particularly in terms of cost efficiency, improved availability of railway assets and better planning of available resources. As modern rail transport moves towards 24-hour railway, the inspection, maintenance and track renewal and upgrade regime will need to be re-thought at a fundamental level. Effective RCM will be a key factor in realistically enabling true round the clock operations. The results presented in this thesis have been part of a six-year research effort with a clear focus on addressing the true industrial need. The findings of this work have led to a re-think within Network Rail regarding the new possibilities arising from the effective use of RCM in designing and implementing more efficient and cost-effective railway operations whilst helping reduce the cost. The use of autonomous sensing systems in the future will change the inspection and maintenance strategies currently used shifting towards a truly prognostic operational strategy

Review of Multiaxial Testing for Very High Cycle Fatigue: From ‘Conventional’ to Ultrasonic Machines

© 2020 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/).Fatigue is one of the main causes for in service failure of mechanical components and structures. With the development of new materials, such as high strength aluminium or titanium alloys with different microstructures from steels, materials no longer have a fatigue limit in the classical sense, where it was accepted that they would have ‘infinite life’ from 10 million (107) cycles. The emergence of new materials used in critical mechanical parts, including parts obtained from metal additive manufacturing (AM), the need for weight reduction and the ambition to travel greater distances in shorter periods of time, have brought many challenges to design engineers, since they demand predictability of material properties and that they are readily available. Most fatigue testing today still uses uniaxial loads. However, it is generally recognised that multiaxial stresses occur in many full-scale structures, being rare the occurrence of pure uniaxial stress states. By combining both Ultrasonic Fatigue Testing with multiaxial testing through Single-Input-Multiple-Output Modal Analysis, the high costs of both equipment and time to conduct experiments have seen a massive improvement. It is presently possible to test materials under multiaxial loading conditions and for a very high number of cycles in a fraction of the time compared to non-ultrasonic fatigue testing methods (days compared to months or years). This work presents the current status of ultrasonic fatigue testing machines working at a frequency of 20 kHz to date, with emphasis on multiaxial fatigue and very high cycle fatigue. Special attention will be put into the performance of multiaxial fatigue tests of classical cylindrical specimens under tension/torsion and flat cruciform specimens under in-plane bi-axial testing using low cost piezoelectric transducers. Together with the description of the testing machines and associated instrumentation, some experimental results of fatigue tests are presented in order to demonstrate how ultrasonic fatigue testing can be used to determine the behaviour of a steel alloy from a railway wheel at very high cycle fatigue regime when subjected to multiaxial tension/torsion loadings.Peer reviewedFinal Published versio