The inspection of structures operating at high temperatures is a major challenge in a variety of industries, including the energy and petrochemical industries. Operators are typically performing nondestructive evaluations using ultrasound to monitor component thicknesses during scheduled shutdowns, thereby ensuring safe operation of their plants. However, despite being costly, this calendar-based approach may lead to undetected corrosion, which can potentially result in catastrophic failures. There is therefore a need for ultrasonic transducers designed to withstand permanent exposure to high temperatures, so as to continuously monitor the remnant thicknesses of structures in real time. This paper discusses the design of a heat-resistant ultrasonic transducer based on a piezoelectric element. The piezoelectric material, the electrodes, the backing layer, the wires and the casing are presented in detail from the acoustic and thermal expansion point of view. Four transducers optimized for 3 MHz were manufactured and tested to destruction in different conditions: (1) 72-h temperature steps from room temperature to 750 ∘C, (2) thermal cycles from room temperature to 500 ∘C and (3) 60 days of continuous operation at >550 ∘C. The paper discusses the results, as well as the effect of temperature over time on the properties of the transducer.
Keywords: bulk acoustic wave sensors; continuous inspection; high temperature; in-service inspection; nondestructive evaluation; piezoelectric; transducer; ultrasonic sensors; ultrasound.