Towards advancing real-time railroad inspection using a directional eddy current probe

In the field of railroad safety, the effective detection of surface cracks is critical, necessitating reliable, high-speed, non-destructive testing (NDT) methods. This study introduces a hybrid Eddy Current Testing (ECT) probe, specifically engineered for railroad inspection, to address the common issue of “lift-off noise” due to varying distances between the probe and the test material. Unlike traditional ECT methods, this probe integrates transmit and differential receiver (Tx-dRx) coils, aiming to enhance detection sensitivity and minimise the lift-off impact. The study optimises ECT probes employing different transmitter coils, emphasising three main objectives: (a) quantitatively evaluating each probe using signal-to-noise ratio (SNR) and outlining a real-time data-processing algorithm based on SNR methodology; (b) exploring the frequency range proximal to the electrical resonance of the receiver coil; and (c) examining sensitivity variations across varying lift-off distances. The experimental outcomes indicate that the newly designed probe with a figure-8 shaped transmitter coil significantly improves sensitivity in detecting surface cracks on railroads. It achieves an impressive SNR exceeding 100 for defects with minimal dimensions of 1 mm in width and depth. The simulation results closely align with experimental findings, validating the investigation of the optimal operational frequency and lift-off distance for selected probe performance, which are determined to be 0.3 MHz and 1 mm, respectively. The realisation of this project would lead to notable advancements in enhancing railroad safety by improving the efficiency of crack detection.