服役钢轨轨底缺陷的超声无损检测方案及装置设计  

Ultrasonic Non-destructive Testing Scheme and Device Design for Rail Base Defects

作　　者：李烨斌 张书增[2] 赵宝 李光耀 汪恒康 LI Yebin;ZHANG Shuzeng;ZHAO Bao;LI Guangyao;WANG Hengkang(Research Institute of Science and Technology,Daqin Railway Co.,Ltd.,Taiyuan Shanxi 030013,China;School of Transportation Engineering,Central South University,Changsha Hunan 410075,China)

机构地区：[1]大秦铁路股份有限公司科学技术研究所,山西太原030013 [2]中南大学交通运输工程学院,湖南长沙410075

出　　处：《中国铁路》2024年第9期195-201,共7页China Railway

基　　金：中国铁路太原局集团有限公司科技研究开发计划项目(A2023G01)。

摘　　要：我国铁路向高速和重载方向发展对服役钢轨的质量提出了越来越高的要求,服役钢轨缺陷危及行车安全,因此及时有效检测服役钢轨中的缺陷具有重要意义。当前主要采用超声方法对服役钢轨轨头、轨腰及轨底中部的缺陷进行检测,尚未有适用于轨底两侧缺陷的超声自动化检测方法,轨底两侧缺陷因无法被有效检出而持续扩展,成为钢轨断轨的主要原因之一。针对当前轨底缺陷检测的不足,提出适用于服役钢轨轨底缺陷的超声无损检测方法,并研制设计相应的检测装置。以检测轨底两侧的横向裂纹为主,通过对超声探头主声束覆盖范围的分析,制定轨底缺陷全面检测的方案;考虑轨底扣件等影响,设计专用的装夹装置,确保探头处于可检测位置,提出淋水耦合方法解决轨底耦合的难题。选取60 kg/m钢轨,在轨底不同位置设计并人工加工为横向裂纹,通过改进的钢轨探伤车进行检测试验,结果表明,研究方法可以实现不同位置缺陷的有效检测。研究成果为后续服役钢轨轨底缺陷乃至全断面缺陷的自动检测提供了有效的解决方案。The development of China’s railway towards high speed and heavy haul has increased the demand for high-quality in-service rails.The defects in the in-service rails endanger train operation safety,so it is important to timely and effectively inspect the defects.At present,ultrasonic method is mainly used to inspect the defects in the rail head,rail web and rail base of in-service rails.There is no automatic ultrasonic inspection method suitable for the defects on both sides of rail base.The defects on both sides of rail base continue to expand as they cannot be effectively inspected,which becomes one of the main reasons for rail breakage.In view of the deficiency of current defect inspection for rail base,this paper proposes an ultrasonic non-destructive testing method,develops and designs the corresponding inspection device.Focusing on inspecting transverse cracks on both sides of rail base,this paper formulates a comprehensive inspection scheme for rail base defects by analyzing the main sound beam coverage of ultrasonic probe.Considering the influence of rail base fastenings,it designs a special clamping device to ensure that the probe is in a detectable position,and proposes a water spray coupling method to solve the problem of rail base coupling.60 kg/m rails are selected,designed and manually processed into transverse cracks at different positions of the rail base,and tested by an improved rail flaw detection car.The results indicate that the method can effectively inspect defects at different positions.The study provides an effective solution for the automatic inspection of subsequent in-service rail base defects and even full-section defects.

关 键 词：超声检测 服役钢轨 轨底缺陷 全断面检测 横向裂纹 钢轨探伤车 

分 类 号：TG115[金属学及工艺—物理冶金]