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ABSTRACT
Laser generation and air coupled detection of ultrasound were combined to produce a hybrid noncontact and remote ultrasonic technique. The
technique is suitable for general testing of a number of structural materials. Using this hybrid technique, guided surface waves were generated to
propagate along the flange, tread and rim edge of a railroad wheel. The
waves complete one revolution around the circumference of the railroad
wheel in 1 ms and interact with surface breaking discontinuities that are
present on the various parts of the wheel. The flexibility and remote nature
of this technique suggest that wayside testing of wheels on a moving train
can be made possible.
Keywords: laser ultrasound, air coupled ultrasound, railroad wheel,
cracks.
INTRODUCTION
The laser/air hybrid ultrasonic technique is a noncontact and remote technique that combines laser generation with air coupled detection of ultrasound. The noncontact and remote nature of this
technique provides it with the flexibility to detect discontinuities in
unfavorable positions and orientations. It has been shown that this
technique can be an effective and easy to use method for rail track
testing (Kenderian et al., 2001; Kenderian et al., 2002). For decades,
optical methods have been widely popular as noncontact and remote ultrasonic detection techniques. However, their efficiency relies heavily on the amount of light reflected back from the surface.
As a result, the curvature, roughness and cleanliness of the reflecting surface all have a negative influence on the amount of light reflecting back to the optical detector. This, unfortunately, renders
these techniques ineffective for many industrial applications including the railroad industry. A comparative study between air
coupled and interferometric detection (Kenderian et al., 2002) or
electromotive force (EMF) detection (Cerniglia and Djordjevic, in
review) of ultrasound demonstrates the superiority of the laser/air
hybrid ultrasonic technique over a purely laser based ultrasonic
technique, within the operating frequencies of the air coupled detector (that is, below 2.25 MHz).
The present paper presents a new technique that would enable
the railroad industry to perform noncontact and remote testing of
railroad wheels while in motion. No method is currently available
to the railroad industry to perform dynamic tests on railroad
wheels.
With a single pulse, a multimode signal was generated. The propagation properties of the signal are a function of the laser pulse
width and intensity, point of impact, surface condition and shape of
the pulse illuminating the surface, but are not affected by the angle
at which a pulse is delivered.
For the detection of ultrasound, a capacitive air coupled transducer (Schindel and Hutchins, 1994; Schindel and Hutchins, 1995)
capable of detecting frequencies between 50 kHz and 2 MHz was
used. The frequency range of this capacitive air coupled transducer
was adequate for the type of discontinuities that cause concern for
the railroad industry. These air coupled transducers are capable of
operating at remote distances exceeding 150 mm (5.9 in.) (Kenderian, 2002). Naturally, higher frequency components attenuate severely in air. Therefore, as the standoff distance between the air coupled transducer and the specimen is increased, the upper limit of
the frequencies retained by the detector is lowered.
Overall signal strength as a function of standoff distance follows
an exponential behavior. Good signals were readily available up to
40 mm (1.6 in.) and useful measurements were possible past 80 mm
(3.2 in.), as shown in Figure 1a. Figure 1b shows that the optimum
detection angle for a rayleigh wave propagating in steel is 6.5 degrees and angular variation of 2 degrees still retains good signal
intensity. The test configuration is that shown in Figure 1c. Using
the acoustic velocity in air Cair = 0.33 mm/s (0.01 in./s), the
rayleigh wave velocity in steel CR = 2.9 mm/s (0.1 in./s) and
90 degree propagation angle of the rayleigh wave in steel, Snells
law calculations confirmed our experimental observation of the
critical refraction angle at 6.5 degrees in air. This is presented in
Equations 1 and 2.
(1)
sin air
C
= air
sin steel Csteel
(2)
0.33
air = sin 1
= 6.5 degrees
2.9
RESULTS
EXPERIMENT
For the generation of ultrasound, a Q-switched Nd:YAG laser
operating at 1064 nm (4.2 10-5 in.) wavelength with pulse durations of 4 to 7 ns and maximum energy of 400 mJ/pulse was used.
* Center for Nondestructive Evaluation, The Johns Hopkins University,
810 Wyman Park Drive, Baltimore, MD 21211; (410) 516-0818; fax (410)
516-7249; e-mail <shant@jhu.edu>.
Materials Science and Engineering Department, The Johns Hopkins
University, 3400 N. Charles St., Maryland Hall 102, Baltimore, MD
21218.
Preliminary experiments performed on a small 32 kg (70 lb) section of the wheel showed that an acoustic signal generated with a
laser line source was more effective than that generated by a laser
point source for the detection of saw cuts. Similar results were reported for surface breaking cracks on rail head (Kenderian et al.,
2001; Kenderian et al., 2002), with a detailed discussion explaining
the underlying cause for the enhanced sensitivity of a line source to
surface discontinuities given in a separate paper (Kenderian et al.,
in publication). Based on these results, the laser source used in this
paper was focused to a line parallel to the direction of the slots,
which is the transverse direction on the wheel.
Materials Evaluation/April 2003 505
(a)
between 0 and 180 degrees, say at 90 degrees, and inclined at 6.5 degrees from the surface normal, optimally detected a signal traveling
the short path, that is counterclockwise according to Figure 2, traveling one quarter of the wheel circumference. Similarly, when this
detector was inclined at 353.5 degrees from the surface normal, it
optimally detects a signal traveling the long path, that is clockwise
according to Figure 2, traveling three quarters of the circumference.
Short path and long path inclinations were denoted with the letters
S and L, respectively.
A 17 mm (0.7 in.) long laser line source was used to generate the
acoustic signal used for the detection of the 16 mm (0.6 in.) slot. Detector standoff distance was kept at 8 mm (0.3 in.) for long path detector inclination and 16 mm (0.6 in.) for short path inclination. Figure 3 shows a broad view, 0 to 1000 s, of a signal generated at
0 degrees and detected at 90 degrees with the detector in the long
path L inclination and slot A located at = 150 degrees. Interestingly, the wheel geometry is such that a rayleigh wave completes one
revolution around the wheel in approximately 1 ms. This is obvious
from the 3.1 and 2.9 m (122 and 115 in.) circumference of the wheel
flange and tread, respectively, and the nearly 3 mm/s (0.1 in./s)
rayleigh wave velocity in rail steel (Bray and Vezina, 1991). Direct,
reflected and transmitted waves are observed.
The first arrival, at 285 s, was a direct wave traveling 90 degrees counterclockwise to the detector, propagating 775 mm (31 in.)
(b)
(c)
Figure 1 Signal strength of capacitive air coupled detector: (a) as a function of standoff distance with optimum 6.5 degrees inclination to the
surface normal; (b) inclination to the surface normal; (c) test configuration under which measurements were taken.
506 Materials Evaluation/April 2003
(a)
(a)
(b)
(b)
(c)
(c)
Figure 5 Frequency analysis with respect to a 5.3 mm (0.2 in.) slot
along a rail wheel: (a) direct waves; (b) reflected waves; (c) transmitted
waves.
508 Materials Evaluation/April 2003
Similarly, when the slot is positioned at = 100 degrees, the reflected wave propagates an additional distance of 163 mm (6.4 in.) to arrive 56 s behind the direct wave, as shown in Figure 6b. In Figure
6c, the corresponding delay associated with the reflected wave
from a slot positioned at = 120 degrees is 168 s, so that the arrival
time of the reflected wave would be 496 s.
(a)
(b)
(c)
(d)
(e)
(f)
Figure 8 The direct wave propagates counterclockwise along the rim edge of the wheel tread, detected with the air coupled transducer positioned at
= 90 degrees in the short path inclination, with 20 mm (0.8 in.) liftoff and crack positions at: (a) 10 degrees; (b) 5 degrees; (c) 10 degrees;
(d) 45 degrees; (e) 80 degrees; (f) 100 degrees.
Materials Evaluation/April 2003 509
(a)
(a)
(b)
(b)
Table 1 Propagation distances and expected arrival times for the waveforms pertaining to Figures 9 and 10
Hole Position from
Acoustic Source
25 mm (1.0 in.)
25 mm (1.0 in.)
65 mm (2.6 in.)
100 mm (3.9 in.)
Figure
9
9
10
10
Detector
Standoff
21 mm (0.8 in.)
21 mm (0.8 in.)
16 mm (0.6 in.)
16 mm (0.6 in.)
fact that the wheel flange had a round edge similar to that of the
rim, the acoustic signal was somewhat confined to the body of the
flange and interacted more pronouncedly with slot A, which extended through most of the flange width. In contrast, along the rim
edge the acoustic signal was free to spread upward towards the
tread and downward towards the hub. In addition, due to the
geometry of the rim edge, slot C was deep in the center but was
quickly reduced to a shallow cut along the edges. The length of slot
C did not extend to a significant portion along the rim width the
way slot A did along the flange. These factors, acting collectively, reduced the detectability of slot C in comparison to the detectability
of slots A and B.
The results shown in Figure 8 demonstrate that the laser/air hybrid ultrasonic technique is capable of detecting saw cuts along the
rim edge of the wheel tread. However, the detected signals were
not as pronounced as those obtained for the wheel flange and tread,
as shown in Figures 4 and 6.
510 Materials Evaluation/April 2003
Direct
107 s
92 s
92 s
Transmitted
107 s
Reflected
123 s
135 s
158 s
the curvature of the wheel, a detector fixed at = 10 degrees was capable of detecting the hole as far as = 15 degrees. Beyond this
range, the hole, generation source and detector fell out of alignment
and the hole was no longer within detection range of the current experimental setup. Table 1 gives signal propagation distances in steel
and air and expected arrival times for the waveforms shown in Figures 9 and 10.
ACKNOWLEDGMENTS
CONCLUSION
The main characteristic of the laser/air hybrid ultrasonic technique is its noncontact and remote method of operation. The technique can be applied on many structural materials in their industrial field condition. That is, although thin layers of dirt, oxides, grease
and other contaminants can slightly dampen the signal detected by
the air coupled transducer, they have a more significant effect on
enhancing the laser generated signal. As a result, a stronger signal is
detected with the presence of such contaminants. The technique
can tolerate surface roughness reasonably well. However, pitting,
spalling and porosities open to the surface can attenuate the surface
wave to a great extent. Surface waves were generated on various regions of the railroad wheel and detected successfully without the
need for modifying the surface through cleaning or polishing. Furthermore, all signals shown in this paper represent single events,
that is averaging techniques were not necessary as a way to improve the signal to noise ratio.
The use of the laser/air hybrid ultrasonic technique introduces
a degree of flexibility to railroad wheel testing that would enable it
to be performed without the need to establish contact between the
probe and the tested part and at relatively remote distances. It was
demonstrated in this paper that 360 degree coverage is possible for
the flange and tread of the railroad wheel with an approximate
time of 1 ms elapsed between generation and detection. For the
rim edge, 90 degree coverage was possible with a single laser
pulse. These results strongly suggest that this technique may be
REFERENCES
Bray, D.E. and G. Vezina, Ultrasonic Applications in the Railroad Industry,
Nondestructive Testing Handbook, second edition: Volume 7, Ultrasonic Testing, P. McIntire, ed., Columbus, Ohio, ASNT, 1991, pp. 594-634.
Cerniglia, D. and B.B. Djordjevic, Ultrasonic Detection by Laser-based Sensors and by Wideband Air-coupled Transducer, Research in Nondestructive Evaluation, in review.
Kenderian, S., B.B. Djordjevic and R.E. Green, Jr., Point and Line Source
Laser Generation of Ultrasound for Inspection of Internal and Surface
Flaws in Rail and Structural Materials, Research in Nondestructive Evaluation, Vol. 13, 2001, pp. 189-200.
Kenderian, S., Advanced Ultrasonic Techniques to Determine the Structural Integrity of Rail Steel, The Johns Hopkins University, Department of
Materials Science and Engineering, PhD dissertation, 2002.
Kenderian, S., B.B. Djordjevic and R.E. Green, Jr., Laser Based and Aircoupled Ultrasound as Noncontact and Remote Techniques for Testing
of Railroad Track, Materials Evaluation, Vol. 60, 2002, pp. 65-70.
Kenderian, S., B.B. Djordjevic and R.E. Green, Jr., Sensitivity of Point and
Line Source Laser-generated Acoustic Wave to Surface Flaws, IEEE
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