In rail wheels, tensile residual stresses are generally harmful, often leading to fatigue failure and cracking. Maintaining compressive stresses within safe limits is essential to prevent them from exceeding the yield limit, which could result in uneven plastic deformation. Although visual inspection may help identify potential issues, it does not provide the stress values needed for informed decision-making. This requires a solution to assess whether the stress values comply with the acceptance levels specified by the norms and standards.
CODA SM is Innerspec's portable EMAT solution for residual stress measurement in train wheels. It complies with EN 13262:2011 and German Standard VPI 09 and has been tested and endorsed by European railway OEMs. With tailor-made software, sensors, and a semi-automated positioner, it ensures accurate and effective stress measurement.
Understanding the Fundamentals of the Technique
EMAT, or Electro Magnetic Acoustic Transducer, is an Ultrasonic Testing Technique that generates the sound in the part inspected instead of the transducer. The technology can generate unique wave modes for accurate stress measurement and doesn’t require the use of a couplant or perfect contact.
A Dual EMAT Sensor generates two orthogonally polarized shear horizontal ultrasonic beams.
- The system measures Time-of-Flight (TOF) in both radial and circumferential directions.
- Time-of-Flight Measurement Accuracy equal to or better than +/0.0002” (0.005 mm).
- Birefringence value is calculated based on TOF measurements.
- Internal stress is directly correlated with birefringence.
The recommended semi-automatic scanner positions and moves the EMAT transducer through the wheel’s rim, obtaining stress profiles at precise locations.
A. Tailor-made for Residual Stress Measurement on Rail Wheels
CODA SM integrates a range of solutions specifically designed for residual stress measurement and tailored to meet the unique requirements of the railway industry. Key features include:
1. Meets EN 13262:2011 & VPI 09:
Supported and tested by leading European railroad ECMs, CODA SM complies with and is recognized under major European standards.
2. Excellent Repeatability and Reproducibility:
Achieves a repeatability of ±5 MPa and a reproducibility of ±50 MPa, meeting standard requirements.
3. Non-contact EMAT Technique:
Enables dry inspection without the need of couplant, accelerating the inspection process. EMAT performs effectively on rough surface conditions, simplifying accurate sensor positioning.
4. Custom Stress Measurement Software:
Designed specifically for residual stress measurement in MPa or psi, this tailor-made software leverages the EMAT technique for highly repeatable readings through precise TOF measurement. CODA’s software displays signal readings and allows for parameter adjustments, ensuring accurate and reliable inspection results.
5. Automatic Reporting:
Features built-in automatic report generation, including residual stress measurements, graphs, snapshots, and operator-entered data. Reports can be customized with your company’s logo and exported in PDF or spreadsheet format.
6. Portability and Easy Operation:
With a lightweight design (1.58 kg), the instrument includes hanging harnesses and a removable phone for convenient use in Confined Spaces, such as under trains or structures. The software’s Operator Mode ensures an easy and reliable click on the buttons needed for the inspection. Innerspec’s NDT-WEB technology permits accessing and operating the instrument from any phone, tablet, laptop, or desktop directly from a web browser, independently of the device’s Operating System, and without having to install potentially unsafe files or apps. Connection to CODA is immediate through the built-in WiFi and/or Ethernet port.
7. Semi-automatic Sensor Positioner for Precise Inspection:
The recommended sensor positioner enables fast and accurate sensor placement across various locations and axes, ensuring compliance with standard requirements.
8. Innerspec Support:
Innerspec’s global network of offices and representatives offers comprehensive commercial and technical support, delivered by factory-trained personnel. Additionally, specialized training in CODA and residual stress measurement is offered.
Also Explore CODA: The Advanced UT Flaw Detector for EMAT and Piezoelectric Sensors
B. Much More than Stress Measurement: A Comprehensive Flaw Detector
CODA SM is the most advanced version of CODA, the first and only compact, High-power UT Flaw Detector capable of operating with both EMAT and piezoelectric sensors, powered by Innerspec’s patented pulser technology.
This enables not only stress measurement but also spot and encoded thickness measurements, as well as flaw detection in various components, all at no additional cost. It maximizes the return on investment in the instrument while expanding the capabilities of workshops, manufacturers, and NDT inspection companies in the railway industry.
CODA SM is compatible with over 20 EMAT sensors and DCUT sensors from Innerspec, and conventional piezoelectric sensors from any manufacturer. It also includes a custom-designed dual EMAT residual stress sensor, making it the most versatile high-performance instrument on the market.
You Can Also Explore About Railway Inspection in our NDT Trends
