Aluminum buffer rods for ultrasonic monitoring at elevated temperatures.

Aluminum (Al) buffer rods, having circular, square, and rectangular cross-section shapes with and without cladding, were experimentally investigated to achieve high performance in ultrasound for industrial process monitoring. Focus was devoted to the signal-to-noise ratio (SNR) aspect in pulse-echo mode because high SNR can make many practical ultrasonic monitoring applications feasible. If the size of the rod cross section can be properly selected, spurious echoes induced in the rod having finite dimensions--due to mode conversion, wave reverberation, and diffraction--do not overlap the desired echoes during pulse-echo measurements. Thus, a sufficient SNR may be obtained using nonclad rods for certain applications, which is of low cost. Clad buffer rods, having the above three shapes and consisting of an Al core and a stainless steel cladding, also were manufactured through thermal spray method. These clad Al rods achieved a SNR of more than 40 dB and had better SNR than clad steel rods. It was shown that the rod with a larger cross-section area exhibited a wider ultrasonic beam. The Al rods are handy in real-time, nonintrusive and nondestructive ultrasonic monitoring.