NDE of Railroads I

Tracks
BREAKOUT A - CORAL I
Audience - General Interest
Audience - Technicians
Industry: Aerospace: In-Space, Aviation
Industry: Energy: Petroleum, Renewable, Power Generation
Industry: NDT Education & Training
Industry: NDT Equipment: Development, Production, Distribution
Industry: NDT Services: Services, Inspection
Industry: Transportation: Automotive, Rail, Marine
Presentation Topic Level - Advanced
Presentation Topic Level - Intermediate
Tuesday, May 12, 2026
10:20 AM - 11:40 AM
Coral I

Speaker

Chengyang Huang
University of California San Diego

Artifact Suppression in Ultrasonic Imaging Using Eigenfilter Processing

Abstract

Artifact suppression in industrial ultrasonic videos is critical for enhancing the visibility of weak structural features such as flaws. Traditional approaches such as frequency-based filtering and baseline subtraction are often limited by assumptions of perfectly separated signal components or fixed spatiotemporal alignment, which rarely hold in practice. More recent studies for artifact removal in medical ultrasound have considered eigenspace filtering that relies on the different spatiotemporal coherence between the consistent artifacts (clutter in medical imaging) and the transient signals of interest. This presentation will adapt the eigenfiltering approach to industrial NDT imaging wheel implementing a Synthetic Aperture Focus Technique (SAFT) applied to flaw imaging in railroad rails using a Rolling Search Unit (RSU). The presentation clarifies some important aspects of eigenfiltering of ultrasound videos. First, it is shown that the eigenfilter effectiveness primarily stems from the large spatiotemporal autocorrelation (rather than cross-correlation) of the pseudo-stationary artifact reflections compared to the small autocorrelation of the transient flaw reflections. In addition, to address the challenges of shifting artifact positions during a scan (a very common occurrence in practical tests), the presentation will propose a novel recursive eigenfilter with rectification that is different from traditional eigenfiltering. This recursive algorithm leverages a nonnegativity constraint consistent with the physics of ultrasound imaging, which iteratively reshapes the eigenspace to optimally suppress the spatiotemporally correlated artifact reflections while highlighting the uncorrelated flaw reflections. The algorithm offers excellent convergence. Experimental results obtained from RSU scanning of both artificial and natural rail flaws demonstrate outstanding filtering performance in the presence of strong artifacts. This filtering approach is widely applicable to many imaging applications involving a scanning setup, beyond rail inspections.

Biography

Francesco Lanza di Scalea is a Professor of Structural Engineering and Director of the NDE&SHM Laboratory at the University of California San Diego. Dr. Lanza di Scalea is an expert in nondestructive evaluation, structural health monitoring, experimental mechanics, and smart structures. He is a Fellow of ASNT, ASME, SEM and ASA. He received the SPIE NDE Lifetime Achievement Award, the ASME NDPD Founders Award, the SHM Person of the Year Award, the Fulbright Scholarship, and the UCSD SE Department’s Best Teacher Award twice. He currently serves on the Editorial Boards of four journals.
Fuben Zhang
Chengdu, China
School Of Physical Science And Technology, Southwest Jiaotong University

Intelligent Phased Array Ultrasonic Defect Detection Method for Solid Axles

Abstract

With the rapid development of high-speed railway technology, the safety of solid axles has become a critical factor in ensuring the reliable operation of trains. However, the complex structural characteristics of axles pose significant challenges to nondestructive testing. On one hand, the wheel seat area, due to the wheel interference fit, is prone to stress concentration, interface roughness, and fretting corrosion, which cause strong noise interference in ultrasonic signals. High noise levels can easily conceal defect signals, greatly limiting their detectability. On the other hand, the journal area generates stable strong echo signals after bearing assembly, and conventional defect evaluation methods struggle to distinguish structural echoes from real defect signals, resulting in a high false alarm rate and continued reliance on manual judgment during the inspection process.
To address these issues, this study proposes two intelligent defect evaluation methods. First, a B-scan defect database for the wheel seat region of solid axles is constructed, and an improved YOLOv5 deep learning algorithm is introduced. By optimizing feature extraction, integrating attention mechanisms and small-object detection layers, and employing active learning to enhance data quality, high-precision recognition of wheel seat defects is achieved. Second, for the journal region affected by bearing press-fit echoes, a machine learning-based evaluation method using manually extracted features and support vector machines (SVM) is designed to effectively distinguish structural echoes from actual defect signals.
Experimental results demonstrate that both methods exhibit excellent performance in solid axle inspection: the defect detection rate of the wheel seat region is significantly improved, and the false alarm rate in the journal region is greatly reduced, providing a feasible new technical solution for intelligent safety inspection of solid axles.

Biography

FuBen Zhang is currently pursuing a Ph.D. at Southwest Jiaotong University. His research focuses on ultrasonic testing, artificial intelligence, signal processing, and ultrasonic imaging.
Mr Meirbek Mussatayev
Assoc. Prof. at Aviation technique and technologie departments
Civil Aviation Academy

Rail Integrity Analysis Using Integrated NDT Methods: A Case Study on Stud Defects

Abstract

Railway infrastructure faces increasingly complex defect phenomena—including rolling contact fatigue (RCF) cracks, studs, and squats—that necessitate the evolution of non-destructive testing (NDT) approaches for timely and dependable identification. This work undertakes a comparative evaluation of three widely utilized inspection modalities: micro-computed tomography (micro-CT), ultrasonic testing employing the total focusing method (UT-TFM), and eddy current testing (ECT). A rail segment removed from operational service is analyzed as a representative case study to examine the detection performance of each technique. Initial results indicate that the three inspection methods offer complementary applications depending on the required resolution. UT‑TFM enables evaluation of sectioned rails without additional cutting, micro‑CT delivers enhanced detail for characterizing specific features, and ECT provides rapid measurements with localized depth sensitivity.

Biography

Meirbek Mussatayev PhD (born 1987), is an Associate Professor in the Department of Aviation Techniques and Technologies at the Civil Aviation Academy, Kazakhstan. He holds two PhDs in Mechanical Engineering - from Guilin University of Electronic Technology (2023), China and the University of Bristol (2025), UK where he developed a directional eddy current probe for real-time automated fibre placement inspection. He previously earned a BSc in Automation Control at Mukhametzhan Tynyshbayev ALT University (2005), Kazakhstan and an MSc in Mechanical Engineering from Tomsk Polytechnic University (2013), Russia. He has more than ten years of industry experience as a senior metrology engineer. His research interests include UAV metrology and certification, eddy current testing, automated inspection, precision manufacturing, and nondestructive evaluation of composite structures.

Session Chair

Gregory Garcia
Senior NDT Level III Engineer-manager
Rocky MountainSteel Mills

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