Application note

Railway solid axle front face UT inspection
Summary
When railway axles fail, the consequences can be disastrous.
For safety, railway solid axles must be inspected regularly
using non-destructive testing (NDT) methods to detect
transversally oriented fatigue cracks.
If inspecting from the axle’s lateral surfaces, methods likeultrasonic testing (UT) or magnetic particle testing (MT)require coating, painting and removal of accessories—suchas brake disks and gears—to allow for proper coupling of theprobe or inspection device.
From the axle’s front face, only UT inspection is feasible
because it is the sole method that can penetrate several
millimeters of material. Unfortunately, solutions based onconventional UT often do not achieve the highest probabilityof detection (POD). That’s because minimizing the numberof inspection angles and transducers may not result in an
optimal inspection. Moreover, many specific setups and kits
may be required for different inspection tasks.

SolutionWith sectorial steering capability, Waygate’s solid axle
mechanized testers (SAMT) combine several conventional
probes into one single phased array (PA) probe. This flexible
solution delivers the required steering angles to optimallycover the axle’s full lateral surface. More reliable inspection ispossible because the SAMT’s single PA probe delivers a lower
risk of loss of the UT coupling.

Combining SAMT with our Mentor UT phased array flaw
detector’s multi-group capabilities lets operators apply
defined steering angles and groups to highlight flaws in
respect to geometry indications. This capability translates toeasier and more informative inspection evaluations.
This solution helps boost the POD—and ultimately enhanceaxle safety—via its steering angle fine tuning capability,
enhanced flaw extension evaluation (through additional
B-S scan views), and dynamic full data recording for postprocessing and traceability.

A single set of groups should be defined to optimally cover
the critical axis areas.
The Mentor UT allows user-defined workflows (apps) for
step by step guidance through the inspection process for aconsistent inspection every time.

Key features/advantages• Combined B-Scan of all groups in preparation. Full A-Scanrecording possible.
• Magnetic coupling within the center bore of the axle via anexchangeable cone.
• Manual probe rotation over approximately 370°.
• Position related data recording thanks to an integrated
encoder.
• Maximal circumferential resolution is 1 (one) degree.
• Phased-Array transducer with 32 or 16 elements in 2 or 4
MHz with a 0° wedge. Both can be replaced by the user.
• Coverage of 55% of the axle length from one end (typical1,2m).
• Inspection time is less than 5min for an entire axle (2 tests),
depending on the UT Requirements.

Mentor UT’s group function capabilityGroups allow for information filtering, custom settings,
enhanced evaluations, and fewer demands on the operator
or evaluator. Each group is completely independent withregard to:• A-scan settings• Delay laws (sweeping range)

Part numbers
0600512SAMT Basic 4
MHz System

Additional
accessories
Mentor UT Base
Unit

Copyright 2020 Baker Hughes Company. All rights reserved.
BHCS34731 (04/2020)

060052001624760162459

Probe; SAMT 4 PA32
Cone Kit; SAMT 90°

Wedge; SAMT 100-180 mm

0162460

Wedge; SAMT 90-100 mm

0600558

Probe SAMT 4 MHz PA160600585

Probe SAMT 2 MHz PA16

118M1844

Presentation Module (Mentor UT)

Mentor-UT-ADAP32-T

Adapter; Mentor UT 32ch/Tyco

100N3883

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