The implementation of this project will modernize the existing prototype of eddy current testing (ECT) sensors and further integrate it into a comprehensive system aimed at early detection of local rail defects, thereby contributing to the prevention of accidents in the railway industry.

Railways remain a crucial mode of transportation; however, rails, as the primary structural component, are exposed to mechanical, thermal, and corrosive loads that lead to surface defects and reduced structural integrity. Increasing train speeds and track capacity require maintaining rails in optimal condition, making non-destructive testing (NDT) critically important. Current inspection methods rely mainly on visual assessment, which depends heavily on inspector expertise and is limited to detecting only surface-level defects. The limited availability of advanced technologies complicates the task of ensuring reliable defect detection and effective data processing.

Eddy current testing (ECT) is becoming increasingly relevant due to its high accuracy and performance. This research focuses on developing optimized ECT sensors for real-time monitoring of rail surface conditions, with particular emphasis on detecting cracks in weld zones and on the side faces of the rail head. The project includes the creation of a new directed sensor and the modernization of existing equipment, which will improve diagnostic accuracy and reduce the risk of missing critical defects.

Special attention is paid to integrating machine learning methods to enhance defect classification and improve the efficiency of signal processing algorithms. The project will increase the commercialization readiness of the equipment, strengthen the competitiveness of domestic NDT technologies, and enable the development of specialized software for the directed ECT sensor.

The main research results are presented in:

10. Mussatayev, R. Kempka, and M. Alanesi, “Towards Advancing Real-Time Railroad Inspection Using a Directional Eddy Current Probe,” Sensors, vol. 24, no. 20, p. 6702, Oct. 2024, doi: 10.3390/s24206702.
11. Mussatayev, Mohammed Ali Fakih, Mark Fitzgerald, Roger Lewis, Abay Beisenbekov, Gulsim Rysbayeva, Berik Rysbayev. Advanced real-time rail monitoring system based on directional eddy current probe, submitted to NDT and E International. It has been assigned the following manuscript number: NDTEINT-D-24-00962.
12. Mussatayev, “Eddy current testing probe for detecting defects in electrically conductive materials of complex shape. Patent for utility model № 9390”

AP23487831 — “Modeling Track Irregularities to Study the Dynamic Performance of Rolling Stock Vehicles of Innovative Designs Based on Theoretical and Experimental Research”

The objective of the project is to provide theoretical and experimental justification for improved and optimal structural components of innovative rolling stock vehicles through modeling vertical and horizontal track irregularities.
The interaction between rolling stock and railway track represents a complex engineering problem. In real operating conditions, rails and wheels have irregularities on the rolling surface and other technological imperfections, which lead to vibrations in the structural elements of rolling stock vehicles. The safety of train operations, as well as the rhythm and cost-efficiency of railway transport, largely depends not only on the design and condition of the railway track, but also on the dynamic characteristics of rolling stock vehicles. Vibrations experienced by rolling stock moving on uneven track also affect passenger comfort. Moreover, such vibrations reduce the operational performance of the rolling stock; therefore, improving ride smoothness and passenger comfort is among the key requirements for modern transport.

The project includes:

• developing a mathematical model that accounts for track irregularities and describes the dynamics of the “vehicle–track” system, taking into consideration rigid diagonal connections and using the fundamental principles of classical mechanics;
• developing a methodology for assessing the reliability indicators of innovative rolling stock equipped with rigid diagonal connections and cassette-type tapered roller bearings, based on fatigue strength criteria;
• creating an engineering calculation method to determine the reliability indicators of stamped-welded rolling stock equipped with cassette-type tapered bearings, using probability theory of failure-free operation;
• developing a methodology for the statistical processing of experimental data in order to construct a power-law fatigue curve equation based on comparative evaluation of test results by amplitudes under actual and equivalent loads;
• formulating a set of design solutions for assessing the dynamic characteristics of innovative rolling stock with consideration of various types of track irregularities.

Theoretical and experimental studies conducted within this project will enable the development of specialized calculation schemes and mathematical models of innovative rolling stock vehicles that account for different types of track irregularities. Consequently, the investigation of the influence of track irregularities on rolling stock dynamics will contribute to enhancing the dynamic performance of innovative rolling stock and developing proposals for amendments to regulatory documents governing geometric parameters of track irregularities.

Key research outputs:

1. Investigation of the Dynamic Performance of Innovative Rolling Stock Based on Track Irregularity Modeling and Theoretical–Experimental Research,
   Solonenko V.G., Musayev Zh.S., Malik A.A., Makhmetova N.M., Akhatov S.T., Kibitova R.K., Ivanovtseva N.V.
   Almaty, 2025 – 222 pages.
   ISSN/ISBN 978-601-325-367-1 — Monograph.
2. Solonenko, V.G.; Musayev, J.S.; Makhmetova, N.M.; Malik, A.A.; Yermoldina, G.T.; Akhatov, S.T.; Ivanovtseva, N.V.
   Dynamic Analysis of Railway Vehicle–Track Interaction: Modeling Elastic–Viscous Track Properties and Experimental Validation.
   Applied Sciences, 2025, 15, 7152. https://doi.org/10.3390/app15137152