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Article · e-Journal of Nondestructive Testing · July 1, 2026

Integrated NDT Approaches for Characterizing Stud-Type Rail Defects: A Comparative Case Study

Meirbek Mussatayev, Ruby Kempka, Roger Lewis, Ian Sinclair, Fernando Alvarez‐Borges, Mohammad Ali Fakih

Meirbek Mussatayev
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Abstract

The increasing complexity of rail defects – such as rolling contact fatigue (RCF) cracks, studs, and squats – demands the advancement of non-destructive testing (NDT) methodologies capable of early and reliable detection. This study presents a comparative assessment of three prominent NDT techniques commonly employed in rail inspection: micro-Computed Tomography (micro-CT), Ultrasonic Testing with the Total Focusing Method (UT-TFM), and Eddy Current Testing (ECT). A sectioned rail specimen extracted from in-service conditions serves as a case study to evaluate the detection capabilities of each modality. Preliminary results from the three NDT techniques demonstrate their distinct capabilities and inherent limitations. The comparative analysis reveals correlations between their outputs and highlights the specific advantages each method provides depending on defect morphology, depth, and the type of information required. Consequently, the suitability of each technique is determined by defect characteristics and the desired diagnostic detail. Rather than being fully interchangeable, the three methods form a complementary toolkit that can be selectively applied to achieve the required inspection depth and resolution. While UT-TFM enables inspection of sectioned rails without the need for further cutting, micro-CT provides a higher level of detail regarding features of interest. The ECT offers rapid assessment with localized depth information.

Non-Destructive Testing TechniquesUltrasonics and Acoustic Wave PropagationRailway Engineering and Dynamicsrail defectssquattingmicro-computed tomography

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