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Rolling Contact Fatigue or Damage (RCF/RCD) presents significant maintenance challenges to railroads across the globe. Quantifying RCF/RCD crack depths and density in rails is important for all railroads to manage their grinding programs effectively and efficiently and being able to conduct ultrasonic testing (UT) of rails for reliable detection of internal fatigue damage. This work focuses on the modeling of Rayleigh waves UT approach to detect and characterize RCF type of defects which can form as: vertical, oblique or branched shaped surface breaking defects in the rail head. Specifically, the transmission coefficient (Tc) of Rayleigh waves was studied using finite element analysis (FEA). The effect of crack tip geometry on Tc values is discussed. The results suggest that for oblique, and branch cracks, characterization based purely on the Tc can be challenging due to symmetric sinusoidal fluctuations in the Tc. A real crack using a micrograph image was also modeled to validate the Tc results for oblique and branched cracks. This points to the need for additional parameters to be identified for efficient and reliable characterization of RCF/RCD type of defects in rails.

Numerical Study of Rayleigh Wave Interaction with Rolling Contact Fatigue Type of Defects