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Simulation and performance study of circular ultrasonic array for tubes' internal inspection.

Ze Xi1, Xiaowei Luo1, Yahui Peng2

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A novel circular array (CA) transducer effectively inspects small diameter tubes, crucial for Modular High Temperature Gas-cooled Reactor heat exchangers. This technology achieves high sensitivity for detecting flaws in critical industrial components.

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Area of Science:

  • Materials Science and Engineering
  • Non-Destructive Testing (NDT)
  • Ultrasonic Transducer Technology

Background:

  • Small diameter tubes, such as those in nuclear reactor heat exchangers, require reliable internal inspection methods.
  • Existing inspection techniques may face limitations in sensitivity and applicability to confined spaces.
  • Modular High Temperature Gas-cooled Reactors (MHTGRs) necessitate advanced NDT for component integrity.

Purpose of the Study:

  • To develop and validate a circular array (CA) transducer for internal inspection of small diameter tubes.
  • To assess the CA transducer's capability for detecting flaws in heat exchanger tubes.
  • To determine the detection sensitivity of the CA transducer in both circumferential and radial directions.

Main Methods:

  • Development of a geometric model and delay law for the CA transducer.
  • Acoustic simulation using k-Wave to analyze beam profiles and focal depths.
  • Fabrication and performance testing of a 64-element prototype CA transducer.
  • Experimental validation using artificial defects (grooves) on tube walls to assess detection sensitivity.

Main Results:

  • Simulation identified optimal aperture size and focal depth (4-element aperture, 1.0 mm focal depth).
  • Experimental results confirmed the CA transducer's detection sensitivity of at least 0.2 mm circumferentially and 0.1 mm radially.
  • The fabricated CA transducer demonstrated effective internal inspection capabilities for small diameter tubes.

Conclusions:

  • The developed circular array transducer is a viable technology for the internal inspection of small diameter tubes.
  • The CA transducer shows significant potential for application in MHTGR heat exchanger tube inspection.
  • The study validates the simulation-driven design approach for optimizing ultrasonic transducer performance.