Safety critical railway components

An ultrasonic inspection process can detect fracture defects in challenging rail-side conditions.

MTC helped Network Rail develop a low-cost, fast and effective inspection solution for rail fastener housings that could become a central element of future routine checks.

Rail fastener housings are a vital component of a track, ensuring the rail is secured to the sleepers. The Eastleigh derailment in January 2020 was caused by several RT60 fastener housings which had fractured and then failed.

An ultrasonic inspection process, using a custom 3D-printed probe holder, was developed by MTC to detect fracture defects in challenging rail-side conditions. The inspection technique allows RT60 fastener housing components to be tested for fracture defects effectively for the first time.

Phil Winship, Principal Engineer, Asset Enhancements Team at Network Rail, said:

Through a targeted selection process MTC helped identify a non-destructive-testing solution to identify where hidden defects are present in a critical component. The work has been instrumental in finding an effective solution quickly and efficiently.