Nonlinear ultrasonic testing has been accepted as a promising manner for evaluating material integrity in an early stage. Stress fatigue is the main threats to train safety, railways examinations for stress fatigue are more significant and necessary. A series of ultrasonic nonlinear wave experiments are conducted for rail specimens extracted from railhead with different degree of fatigue produced by three-point bent loading condition. The nonlinear parameter is the indicator of nonlinear waves for expressing the degree the fatigue. The experimental results show that the sensitivity of a third harmonic longitudinal wave is higher than second harmonic longitudinal wave testing. As the same time, collinear wave mixing shows strong relative with fatigue damages than a second longitudinal wave NDT method and provides more reliable results than third harmonic longitudinal waves nonlinear testing method.

An effective method to inspect inaccessible nuclear power facility by interface wave which propagate along the shrink fit boundary of reactor head is proposed in this study. Reactor head is relatively thick to inspect from the outside of reactor by conventional ultrasonic testing. The proposed interface wave can propagate a long distance from the fixed transducer position. The inside of nuclear reactor is limited to access due to the high radiation, so transducers are located at outside of nuclear facility and interface wave propagates into the nuclear reactor for defect detection. The numerical simulation and experiments were carried out to validate the effectiveness of the proposed interface wave inspection method. Various defect cases simulating field failures are also presented with satisfactory detectability by the proposed technique with the features for defect classification.