The rapid development of high-speed and heavy-haul railways caused rapid rail defects and sudden failure. This requires more advanced rail inspection, i.e., real-time accurate identification and evaluation for rail defects. However, existing applications cannot meet future demand. In this paper, different types of rail defects are introduced. Afterwards, methods that have the potential to achieve rapid accurate detection and evaluation of rail defects are summarized, including ultrasonic testing, electromagnetic testing, visual testing, and some integrated methods in the field. Finally, advice on rail inspection is given, such as synchronously utilizing the ultrasonic testing, magnetic flux leakage, and visual testing for multi-part detection. Specifically, synchronously using the magnetic flux leakage and visual testing technologies can detect and evaluate surface and subsurface defects, and UT is used to detect internal defects in the rail. This will obtain full rail information, to prevent sudden failure, then ensure train ride safety.

Wheel slips often produce wheel/rail damage, threatening the operation safety, and increasing the maintenance cost of contact-type railways. To understand the characteristics of wheel slips for further development of more accurate slip protection methods, this study employs a validated explicit finite element (FE) method to evaluate the transient wheel-rail rolling/slipping contact behaviors. The contact during the traction of the wheel from both standstill status and moving status is focused. Friction and traction coefficients are the two most crucial factors affecting the wheel slips. Conditions of partial and full slips within the contact patch are determined by setting different combinations of the traction and friction coefficients. The contact behaviors including stick-slip, partial slip, full slip, surface stress, and wear are studied. It is revealed that wheel slips may occur not only in the case where the traction coefficient exceeds the limiting value, but also when being slightly smaller. As a consequence, wheel slips can produce much larger wear-rate. This study provides an insight into the wheel slipping/spinning mechanism and theoretical guidance for the development of more accurate control methods of wheel slips.

Wheel burn can affect the wheel–rail contact state and ride quality. With long-term operation, it can cause rail head spalling or transverse cracking, which will lead to rail breakage. By analyzing the relevant literature on wheel burn, this paper reviews the characteristics, mechanism of formation, crack extension, and NDT methods of wheel burn. The results are as follows: Thermal-induced, plastic-deformation-induced, and thermomechanical-induced mechanisms have been proposed by researchers; among them, the thermomechanical-induced wheel burn mechanism is more probable and convincing. Initially, the wheel burns appear as an elliptical or strip-shaped white etching layer with or without deformation on the running surface of the rails. In the latter stages of development, this may cause cracks, spalling, etc. Magnetic Flux Leakage Testing, Magnetic Barkhausen Noise Testing, Eddy Current Testing, Acoustic Emission Testing, and Infrared Thermography Testing can identify the white etching layer, and surface and near-surface cracks. Automatic Visual Testing can detect the white etching layer, surface cracks, spalling, and indentation, but cannot detect the depth of rail defects. Axle Box Acceleration Measurement can be used to detect severe wheel burn with deformation.

High-speed railway administrations are particularly concerned about safety and comfort issues, which are sometimes threatened by the differential deformation of substructures. Existing deformation-monitoring techniques are impractical for covering the whole range of a railway line at acceptable costs. Fortunately, the information about differential substructure deformation is contained in the dynamic inspection data of longitudinal level from comprehensive inspections trains. In order to detect potential differential deformations, an identification method, combining digital filtering, a convolutional neural network and infrastructure base information, is proposed. In this method, a low-pass filter is designed to remove short-waveband components of the longitudinal level. Then, a one-dimensional convolutional neural network is constructed to serve as a feature extractor from local longitudinal-level waveforms, and a binary classifier of potential differential deformations in place of the visual judgement of humans with profound expertise. Finally, the infrastructure base information is utilized to further classify the differential deformations into several types, according to the positional distribution of the substructures. The inspection data of four typical high-speed railways are selected to train and test the method. The results show that the convolutional neural network can identify differential substructure-deformations, with the precision, recall, accuracy and F1 score all exceeding 98% on the test data. In addition, four types of deformation can be further classified with the support of infrastructure base information. The proposed method can be used for directly locating adverse substructure deformations, and is also becoming a promising addition to existing deformation monitoring methods.