All It’s Cracked Up To Be: Rail Flaw Detection

ENSCO’s Ultrasonic Rail Flaw System uses wheel probe technology to inspect rails for defects across their full cross-section.

Courtesy of ENSCO Rail

ATLANTA - From the January 2025 issue of Railway Track & Structures, this vendor product spotlight focuses on rail flaw detection solutions.

Over time, rails can develop cracks and/or corrosion. These can lead to weakened rails if not properly addressed and maintained. For detecting these potential flaws in the rails, companies have developed technologies to inspect and identify said flaws. Preventive measures such as these listed here allow railroads to be proactive in keeping their networks safe and operational. A failure to do so can lead to disruptions, delays, and derailments. RT&S reached out to several players who offer rail flaw detection solutions to extend the life of the rails and keep operations running smoothly. 

ENSCO told RT&S of its “Ultrasonic Rail Flaw System (URFS) delivers advanced rail flaw detection with unmatched precision and reliability. Designed for deployment on hi-rail vehicles, the URFS uses innovative wheel probe technology to inspect rails for defects across their full cross-section. Each wheel probe features multiple ultrasonic probes, including zero-degree, 45-degree, and 70-degree configurations, to detect flaws in the rail head, web, and base. Side-looking probes enhance coverage for head/web separations and other critical areas. The system integrates seamlessly with advanced user interfaces, providing real-time A-Scan and B-Scan data, defect lists, and rail profile views. Field-tested over 12 months, including head-to-head comparisons, URFS consistently demonstrates superior detection accuracy. ENSCO’s proprietary Rail Defect Farm supports continuous innovation, allowing the URFS to detect a wide range of defects such as transverse fractures, bolt hole cracks, and vertical split heads. The URFS sets a new standard in rail flaw detection, ensuring safer, more reliable railway operations.” 

Wabtec’s KinetiX Inspection Technologies is an advanced ultrasonic rail flaw detection technology. According to Wabtec, its “newest division leverages AI and expertise to optimize rail inspections. KinetiX Inspection Technologies, the newest division within Wabtec Digital Intelligence, is revolutionizing the world of ultrasonic rail flaw detection. By combining cutting-edge technology with unparalleled expertise, KinetiX is empowering rail operators to maintain the highest levels of safety and efficiency. At the heart of KinetiX’s offering is a comprehensive suite of ultrasonic testing services and equipment. Leveraging Wabtec’s Advanced Technology Team and the power of Artificial Intelligence, KinetiX’s defect recognition software has been enhanced to provide advanced confidence level assessments. This allows operators to focus their efforts on the most critical ultrasonic indications, ensuring the highest-risk internal defects are addressed promptly. 

‘These technological advancements, coupled with our highly skilled operators, enable us to deliver the most efficient and targeted rail inspections,’ said Dave Staton, General Manager. He continued, ‘By optimizing the inspection process, we help our customers maximize asset availability and reduce operational costs, all while upholding the strictest safety standards.’ KinetiX’s commitment to innovation and excellence is evident in every aspect of its operations. From the deployment of the latest inspection equipment to the ongoing training and development of its expert team, the division is dedicated to providing the rail industry the most advanced solutions available. ‘KinetiX Inspection Technologies represents the future of rail flaw detection,’ added Staton. ‘By leveraging Wabtec’s extensive resources and expertise, KinetiX is poised to redefine the industry, setting new benchmarks for safety, efficiency, and reliability.’” 

When asked about its rail flaw detection, Herzog said it “continues to set new benchmarks in rail testing technology with its innovative 8000 Series ultrasonic rail testing platform. Designed to enhance efficiency and reliability, this cutting-edge system incorporates three groundbreaking components: the Smart Probe, auto-centering, and utility bed. The Smart Probe features next-generation ultrasonic technology that has undergone three significant revisions, improving installation, maintenance, and data transfer. Enhanced software and an improved signal-to-noise ratio ensure cleaner, more reliable test results, simplifying operator decision-making and setting new standards for ultrasonic testing. The auto-centering system offers advanced functionality with tablet-based controls and fully autonomous rail tracking. Seamlessly integrated with the Smart Probes, this system delivers precise testing capabilities, even under demanding conditions. Updates to the utility bed introduce modular housing for specialized equipment, enabling quick and efficient transfers to new chassis with minimal downtime. Improved cable protection and streamlined field maintenance further boost operational readiness. Herzog’s focus on innovation and continuous improvement is evident in the progress achieved over the past year. The team is targeting tandem testing readiness by the end of the year, a milestone that marks a major step forward in the evolution of the 8000 Series and reinforces Herzog’s position at the forefront of rail testing technology. 

‘Our team is dedicated to advancing industry standards and overcoming critical challenges in rail flaw detection. Herzog’s significant investments reflect our commitment to pushing the boundaries of what’s possible,’ Vice President of Rail Testing Max Lafferty said. ‘Through active feedback loops with our customers and employees, we continually refine our projects to solidify Herzog’s position as the premier rail testing company in North America.’ 

Orgo-Thermit, a Goldschmidt company, has its “own Eddy Current Measurement service which inspects the rail running surface, and more importantly, the gauge corner of the rail for instances of rolling contact fatigue (RCF) damage. Our technology encompasses both an onboard train mounted system designed for continuous recording during revenue service hours as well as a manual operated trolley with eight probes strategically located to identify underlying conditions of defect prone areas of the rail surface. The Eddy Current method is based on the principle of generating circular electrical currents in a conductive material. These electrical currents are able to identify abnormalities in the rail surface and can indicate the depth of surface defects, such as head checks, up to 0.106 inches (2.7 mm). By identifying the scope of the RCF, customers will be better informed to take preventive actions such as either rail grinding or rail replacement in extreme cases.” 

Orgo-Thermit told RT&S that it has been “using this technology to support our grinding services on a number of Transit agencies. By performing a scan prior to grinding it allows us to identify the depth of RCF. This in turn has allowed us to then put together a grinding plan to address those areas with more significant RCF knowing the exact depth of the RCF and how much material to remove. This also allows us to know which areas of track do not require grinding. By offering this level of comprehensive service it offers two benefits to the customer. Firstly, it allows us to knowingly remove the RCF from the track based on the measurements but just as importantly we know where not to grind which means that the rail is not being ground unnecessarily. As we continue to perform this analysis on an annual basis it will allow us to develop an in-depth analysis and understanding of the development of RCF of the customer’s track and how to develop a comprehensive grinding strategy.”