Under the Association of American Railroads’ (AAR) Strategic Research Initiatives (SRI) Program, MxV Rail analyzed four freight railcar axles with multiple visible cracks in the journal fillet radius. These axles were inspected at a repair facility, deemed condemnable, and removed from service in accordance with AAR standards.1 The primary objective of this research was to enhance the understanding of fatigue cracks developing in the journal radius area, a location that is obscured by the bearing backing ring. Additionally, MxV Rail researchers evaluated the feasibility of using eddy current testing (ET) nondestructive evaluation (NDE) technology for inspecting axles, with a focus on the detection and characterization of surface and near-surface discontinuities, including cracks. Background Railcar axles are essential for connecting wheels and bearings and supporting the weight of railcars to ensure the safe transportation of freight and passengers. Made from heat-treated carbon steel, North American freight car axles are designed and…
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