Structural health condition monitoring of rails using acoustic emission techniques

In-service rails can develop several types of structural defects due to fatigue and wear caused by rolling stock passing over them. Most rail defects will develop gradually over time thus permitting inspection engineers to detect them in time before final failure occurs. In the UK, certain types of severe rail defects such as tache ovales, require the fitting of emergency clamps and the imposure of an Emergency Speed Restriction (ESR) until the defects are removed. Acoustic emission (AE) techniques can be applied for the detection and continuous monitoring of defect growth therefore removing the need of imposing strict ESRs. The work reported herewith aims to develop a sound methodology for the application of AE in order to detect and subsequently monitor damage evolution in rails. To validate the potential of the AE technique, tests have been carried out under laboratory conditions on three and four-point bending samples manufactured from 260 grade rail steel. Further tests, simulating the background noise conditions caused by passing rolling stock have been carried out using special experimental setups. The crack growth events have been simulated using a pencil tip break.