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
Francesco Lanza Di Scalea
Professor
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.
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.
Gavin Dao
Director Of Business Development
Tpac
Backscattering-Based Ultrasonic Imaging TFM and Phase-Coherence Methods for Railway Components
11:00 AM - 11:20 AMAbstract
Ultrasonic backscattering techniques enable the evaluation of internal integrity and microstructural properties in metallic components—an essential capability in safety-critical sectors such as the railway industry. This work investigates the application of backscattering-based ultrasonic imaging to the inspection of railway rails and wheels, which are subject to cyclic loading, wear, and fatigue that can lead to internal defects invisible from the surface.
Backscattering imaging reconstructs the field scattered by microstructural inhomogeneities using coherent beamforming algorithms. Linear approaches such as the Delay-And-Sum (DAS) and its full-matrix implementation, the Total Focusing Method (TFM), provide baseline reflectivity maps of the material. More advanced techniques—Phase Coherence Imaging (PCI) and other phase-based metrics—enhance image contrast by exploiting phase correlation among the received signals. In addition, nonlinear energy-based beamforming methods like the power Delay-And-Sum (pDAS) further increase robustness and defect detectability by emphasizing coherent energy while suppressing incoherent backscatter.
Applied to rails and wheels, these methods allow accurate assessment of surface-hardening depth, early detection of subsurface cracks, and microstructural evaluation correlated with destructive validation. The combination of linear, nonlinear, and coherence-based imaging provides fast, non-destructive characterization with reduced operator dependency and improved reliability for predictive maintenance.
In conclusion, ultrasonic backscattering imaging represents a powerful and evolving framework for ensuring the safety and durability of railway components—bridging structural defect detection with microstructural sensitivity to prevent failures and extend service life.
Backscattering imaging reconstructs the field scattered by microstructural inhomogeneities using coherent beamforming algorithms. Linear approaches such as the Delay-And-Sum (DAS) and its full-matrix implementation, the Total Focusing Method (TFM), provide baseline reflectivity maps of the material. More advanced techniques—Phase Coherence Imaging (PCI) and other phase-based metrics—enhance image contrast by exploiting phase correlation among the received signals. In addition, nonlinear energy-based beamforming methods like the power Delay-And-Sum (pDAS) further increase robustness and defect detectability by emphasizing coherent energy while suppressing incoherent backscatter.
Applied to rails and wheels, these methods allow accurate assessment of surface-hardening depth, early detection of subsurface cracks, and microstructural evaluation correlated with destructive validation. The combination of linear, nonlinear, and coherence-based imaging provides fast, non-destructive characterization with reduced operator dependency and improved reliability for predictive maintenance.
In conclusion, ultrasonic backscattering imaging represents a powerful and evolving framework for ensuring the safety and durability of railway components—bridging structural defect detection with microstructural sensitivity to prevent failures and extend service life.
Biography
Héctor Calas, PhD in Physics, is Application Manager at TPAC in Nantes, France, with 23 years of experience in advanced ultrasonic testing. His expertise includes phased array, TFM, and air-coupled UT techniques, with a strong focus on integrating machine learning and intelligent tools to enhance industrial NDT workflows and support scalable, high-precision inspection strategies.
Gulsim Rysbayeva
Leading researcher
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
Gulsim Rysbayeva is an electrical engineer specializing in Automation and Control, focusing on intelligent condition monitoring of induction motors and machine-learning-based diagnostics. She has over 10 years of experience in simulation modeling, vibration diagnostics, fault identification, and neural network analysis for industrial equipment. She also works in non-destructive evaluation and contributes to project AP26102347 on developing directional eddy-current probe systems for railway defect detection. Her expertise includes signal processing, defect characterization, and designing machine-learning algorithms for cracks, surface defects, and structural abnormalities in rail components, as well as modeling and predictive maintenance of electromechanical systems.
Session Chair
Gregory Garcia
Senior NDT Level III Engineer-manager
Rocky MountainSteel Mills