On-Line Ultrasonic Testing of Rails at Whyalla

The study investigates on-line ultrasonic testing as a method for detecting flaws and assessing non-metallic inclusions in rails, traditionally a difficult task. The objective is to provide a reliable, non-invasive solution that overcomes the limitations of current sampling methods. The methodology involves using dual horizontal head probes and a jet probe assembly with crystal transducers to enhance detection capabilities. The system enables real-time measurement by circulating water, thus facilitating consistent data acquisition regardless of rail speed. Results indicate that this ultrasonic testing method significantly improves the detection of larger inclusions, such as pipes and hydrogen flakes, as well as helps in monitoring rail quality without the drawbacks of conventional sampling methods. The technology proves to be a valuable tool in maintaining and improving rail integrity, showcasing the advantages of on-line ultrasonic methods in industrial applications.