Verification of the use of Micro-CT scanning to assess the features of entire squat type defects

Abstract

Squats and studs are defects in railheads that share features, but have different causes. This paper examined four squat and stud samples from three different traffic environments to compare features using μ-CT X-ray scans, surface and subsurface inspection. μ-CT scanning has been used before as a non-destructive method to investigate rail defects, but not the entire defect. The scans were verified and allowed the identification of areas of interest when sectioning the samples further. The scan volumes were also used to create 3D models of the crack networks for the 3 samples that were scanned. All defects contain similar superficial features but the depth and severity of the subsurface damage varies.This work provides a visualisation of the 3D nature of studs in a way not seen before, as a 3D model the crack network from an in-service defect. The models of two of the defects showed the influence of hollow wheels initiating defects, as the crack seemed to initiate on the field side, grow down and towards the gauge side, before resurfacing as the longitudinal crack noted in all four defect samples. One sample is believed to have initiated due to contamination of the weld and the only squat sample, which failed in track, was believed to be ingot cast steel containing many inclusions.Three samples were studs and one was a squat. Each defect developed for different reasons, although the two metro samples were similar. One of the studs shows branching of cracks that, based on its changing angle of growth, could continue to grow into transverse defects, breaking the rail. The three defects that were scanned would all be classed as studs, but their crack morphology varies, possibly because they are all from different traffic environments. They also show slight differences to other studs in literature.