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Railway inspection
- 1. หลักการและมาตรฐาน การตรวจสอบแบบไม่ทาลายของรางรถไฟ Principle and standardof NDT for railway inspection กิตติพงค์ นิมากร kittiphong@tistr.or.th
- 3. 29/03/2561 Present by: Mr.Kittiphong Nimakorn, Email : kittiphong.n@ku.th Department : Materials Engineering, Faculty : Engineering, University : Kasetsart 3 Manufacturing process in Rail Steel
- 5. 29/03/2561 Present by: Mr.Kittiphong Nimakorn, Email : kittiphong.n@ku.th Department : Materials Engineering, Faculty : Engineering, University : Kasetsart Rail steel grades Chemical composition % Mechanical properties C Si Mn Pmax Smax Cr Mo Rm N/mm 2 A5 % HBW R350HT 0.72- 0.80 0.15- 0.58 0.70- 1.20 0.020 0.025 - - >1175 9 350- 390 R260 0.60- 0.82 0.13- 0.60 0.65- 1.25 0.030 0.030 - - 880 10 260- 300 The chemical composition of rail steels UIC 60 by EN 13674-1 (wt %) 5 Composition of material
- 6. 29/03/2561 Present by: Mr.Kittiphong Nimakorn, Email : kittiphong.n@ku.th Department : Materials Engineering, Faculty : Engineering, University : Kasetsart Rail steel Grade Hardness Head hardened Remark R260 260 HBW none All straight tract and main line curves of greater than 400 m R350HT > 350 HBW Heat treatment Use in station, switches, crossings and main line curves of 400 m or less 60E1 to EN 13674-1 1999 Flat Bottom symmetrical railway rails 60 kg/m and above. Data:Kingdom of Thailand, Ministry of Transport Mass Rapid Transit Authority of Thailand, Green Line Project (Bearing – Samutprakan) Data:Kingdom of Thailand, Ministry of Transport Mass Rapid Transit Authority of Thailand, Blue Line Project (Hua Lamphong – Lak Song) 6 Rail Section and Materials
- 7. 29/03/2561 Present by: Mr.Kittiphong Nimakorn, Email : kittiphong.n@ku.th Department : Materials Engineering, Faculty : Engineering, University : Kasetsart 7 Eutectoid Transformation Rate; T
- 8. 29/03/2561 Present by: Mr.Kittiphong Nimakorn, Email : kittiphong.n@ku.th Department : Materials Engineering, Faculty : Engineering, University : Kasetsart Data: P.I. Christodoulou et al. / Theoretical and Applied Fracture Mechanics 83 (2016) 51–59. http://onlinepubs.trb.org/Onlinepubs/trr/1992/1341/1341-008.pdf 8 Microstructure of pearlite in rail steel Head : fine-pearlitic ==> high wear and RCF resistance Transition zone Web & foot : pearlitic with high ductility ==> high endurance limit
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- 14. 29/03/2561 Present by: Mr.Kittiphong Nimakorn, Email : kittiphong.n@ku.th Department : Materials Engineering, Faculty : Engineering, University : Kasetsart Data: Check List of Alumino Thermit Welding type SkV-E. 14 Welding Procedure for Thermite (Alumino Thermit Welding type SkV-E)
- 15. 29/03/2561 Present by: Mr.Kittiphong Nimakorn, Email : kittiphong.n@ku.th Department : Materials Engineering, Faculty : Engineering, University : Kasetsart Data: Technical Data The Thermit SkV-E Process : Thermit Welding (GB) Ltd. 15 Temperature in Welding Method
- 16. 29/03/2561 Present by: Mr.Kittiphong Nimakorn, Email : kittiphong.n@ku.th Department : Materials Engineering, Faculty : Engineering, University : Kasetsart 16 Microstructure of welding
- 17. 29/03/2561 Present by: Mr.Kittiphong Nimakorn, Email : kittiphong.n@ku.th Department : Materials Engineering, Faculty : Engineering, University : Kasetsart 17 Heat Affected Zone(HAZ)
- 18. 29/03/2561 Present by: Mr.Kittiphong Nimakorn, Email : kittiphong.n@ku.th Department : Materials Engineering, Faculty : Engineering, University : Kasetsart Data: Technical Data The Thermit SkV-E Process : Thermit Welding (GB) Ltd. 18 The SkV-E Welding Method
- 19. 29/03/2561 Present by: Mr.Kittiphong Nimakorn, Email : kittiphong.n@ku.th Department : Materials Engineering, Faculty : Engineering, University : Kasetsart 19 Discontinuity in Railroad
- 22. Failure Classification basedon Nature of Failure ❖Fatigue cracks failure ❖Rolling contact fatigue cracks ❖Wear failure ❖Material deformation failure ❖Shear failure Failure Modes and Effects Analysis
- 23. Failure Modes andEffects Analysis
- 24. Rail head crackswith internal origin : kidney-shape crack( Subsurface origin ) This type crack usually initiates from manufacturing defects which show up when the rail starts to age. Accumulative tonnage borne or progressive cracking of the rail head leads to kidney-shape flaw. initiation Failure Modes and Effects Analysis
- 25. Transverse Rail FootCracks This is described as a progressive fracture in the base of the rail which develops substantially on a transverse plane. Transverse cracks are usually initiated from the outer edge of the foot (Galling) due to wear and/or corrosion at the rail support. As a result of relatively high bending, torsional and residual stresses, very small underside foot cracks can lead to complete rail fracture. initiation Failure Modes and Effects Analysis
- 26. Longitudinal Rail FootCracks This defect is thought to be caused by improper seating of the rail or poor manufacturing. The defect usually starts as a vertical longitudinal split which can be seen away from the center line of the foot that probably causes a piece of the foot to break away, and more severe damages happen near the center line of the foot by causing a complete fracture of the rail. Failure Modes and Effects Analysis
- 27. Longitudinal Vertical andHorizontal Cracks(Rail Web Cracks) Cracks in the web usually originate from poor manufacturing. These can be in a vertical (piping) or horizontal direction leading to rail fractures. They are initiated at shrinkage cracks at the outer edge of the weld collar. Typically, impact loading is a contributing factor. Failure Modes and Effects Analysis
- 28. Head Checks Surface fatigueoriginates from the stress-exhausted surface layer of the material. As wear rates on the rails are low, the metal remains in place longer and finally reaches the fatigue limit which lead to head check cracks. Head checks are groups of fine surface cracks at the running (gauge) corner of the rail with a typical interspacing of 0.5–10 mm. They run initially into the interior of the rail at an angle of 15-30° against traffic direction. Head check cracks normally shallow and removed quite easily by rail grinding.
- 30. Squats This type offailure is characterized by the appearance of micro cracks below the surface of the tracks. Squat cracks occur due to high dynamic load of track leading to rolling contact fatigue. At first, these cracks look like a small dark dot. They then become enlarged from the bottom of the dot and grow at a shallow angle in the longitudinal direction. Sometimes the growth of cracks under the surface is in direction to the gauge corner that is common in moving cross frogs. Cracks finally turn down vertically and can eventually result in a rail breakage. The significant characteristic of squats usually appears on the running surface and less commonly from the gauge corner. Welding is known as common treatment of squats defect.
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- 35. 35 Introduction Non DestructiveExamination
- 36. 36 Introduction Non DestructiveExamination
- 37. 37 4. Methods andtechniques: Surface - Visual - Replica - Liquid penetrant - Magnetic particle - Electric current - Eddy current - Ultrasonic - Acoustic emission - Thermography Interior - Magnetic particle (limited use) - Magnetic field - Electric current perturbation - Eddy current - Microwave - Ultrasonic - Acoustic emission - Radiography - X-ray computed tomography - Neutron radiography - Thermography (possible) Introduction Non Destructive Examination
- 38. 38 3. Applications: Engine parts,Frame. Automotive Airframes , Spaceframes , Propellers , Reciprocating Engines, Gas Turbine Engines , Rocketry. Aviation / Aerospace Structures , Bridges. Construction Machine parts, Castings and Forgings. Manufacturing Pressure vessels ,Storage tanks ,Welds ,Boilers ,Heat exchangers ,Turbine bores ,In-plant Piping. Industrial plants Pipelines , Railways , Tubular NDT, for Tubing material, Corrosion Under Insulation (CUI) ,Amusement park rides, Submarines and other Naval warships. Miscellaneous Introduction Non Destructive Examination
- 39. 39 Introduction Non DestructiveExamination
- 40. 40 Introduction Non DestructiveExamination
- 41. Borescopes Introduction Non DestructiveExamination
- 42. Robotic Crawlers Video Borescopes RigidBorescopes Flexible Fiberscopes Introduction Non Destructive Examination
- 43. Introduction Non DestructiveExamination Applications: Vibration Analysis
- 44. 44 Introduction Non DestructiveExamination
- 45. 45 Introduction Non DestructiveExamination
- 46. 46 ►Inspection Steps: “Cont.” IntroductionNon Destructive Examination
- 47. 47 Introduction Non DestructiveExamination
- 48. Introduction Non DestructiveExamination
- 49. 49 ►Features: Introduction NonDestructive Examination
- 50. 50 3. MagneticParticle Inspection: Introduction Non Destructive Examination
- 51. 51 Introduction Non DestructiveExamination
- 52. 52 ►Inspection Steps:“Cont.” Introduction Non Destructive Examination
- 53. 53 Introduction Non DestructiveExamination
- 54. 54 Introduction Non DestructiveExamination 3. Magnetic Particle Inspection:
- 55. 55 Introduction Non DestructiveExamination
- 56. 56 ►Limitations ofMagnetic Particle Inspection: Introduction Non Destructive Examination
- 57. 57 4. Ultrasonictesting: Introduction Non Destructive Examination
- 58. 58 Introduction Non DestructiveExamination
- 59. 59 Introduction Non DestructiveExamination
- 60. 60 Introduction Non DestructiveExamination
- 61. 61 Introduction Non DestructiveExamination
- 62. 62 Introduction Non DestructiveExamination 4. Ultrasonic testing:
- 63. 63 5. Radiographic(X-ray) testing: Introduction Non Destructive Examination
- 64. 64 Introduction Non DestructiveExamination
- 65. 65 Introduction Non DestructiveExamination
- 66. 66 Introduction Non DestructiveExamination
- 67. Introduction Non DestructiveExamination
- 68. Introduction Non DestructiveExamination
- 69. Introduction Non DestructiveExamination
- 70. Introduction Non DestructiveExamination 5. Radiographic (X-ray) testing:
- 72. Introduction Non DestructiveExamination Applications: Vibration Analysis
- 73. Infrared and ThermalTesting
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