High Temperature Long-term Online Ultrasonic Monitoring Based on CCBT Piezoelectric Ceramic Transducers

doi:10.3901/JME.260493

Abstract

Abstract: Long-term service of pressure equipment under high-temperature conditions and fluid erosion can easily induce material damage such as crack initiation and propagation. Sudden appearance of cracks caused by various factors may rapidly lead to operational failure and catastrophic consequences. To address the challenge of timely detection of abrupt defects in high-temperature equipment through conventional periodic shutdown inspections, a high-temperature resistant piezoelectric ultrasonic transducer is successfully developed based on a Ce-doped bismuth-layered piezoelectric ceramic (Ce-CaBi₄Ti₄O₁₅, CCBT). Experimental results demonstrate that CCBT exhibits a Curie temperature of 790 ℃. Within the temperature range from room temperature to 450 ℃, its piezoelectric d₃₃ coefficient and DC resistivity remain at 22 pC/N and 250 kΩ·m, respectively, showing excellent thermal stability. The coefficient of thermal expansion (10.45×10^-6/℃) closely matches that of common high-temperature equipment materials such as carbon steel and nickel-chromium steel, effectively preventing structural failure caused by thermal stress. By integrating CCBT transducers with a self-developed ultrasonic monitoring system and implementing high-temperature sound velocity correction, the system achieved long-term precise monitoring of 1 mm through-hole defects in P92 steel specimens at 460 ℃, with detection errors below 2% and a mean time between failures(MTBF) of 1 008 hours. The proposed monitoring technology demonstrates outstanding high-temperature stability and detection accuracy, offering a potential solution for continuous in-service non-destructive monitoring of high-temperature equipment.

Key words: bismuth layered piezoelectric ceramics, piezoelectric ultrasonic transducer, ultrasonic monitoring, high-temperature online monitoring, high-temperature ultrasonic velocity correction

CLC Number:

TB559

YANG Zhen, LI Jian, ZHAO Kefeng, CHEN Zhicheng, HU Zheng, QIU Xunlin, XIANG Yanxun. High Temperature Long-term Online Ultrasonic Monitoring Based on CCBT Piezoelectric Ceramic Transducers[J]. Journal of Mechanical Engineering, 2026, 62(10): 83-92.

Add to citation manager EndNote|Reference Manager|ProCite|BibTeX|RefWorks

URL: http://www.cjmenet.com.cn/EN/10.3901/JME.260493

http://www.cjmenet.com.cn/EN/Y2026/V62/I10/83

References

[1] Gong Wendong，Akbar M F，Jawad G N，et al. Nondestructive testing technologies for rail inspection：A review[J]. Coatings，2022，12(11)：1790.
[2] Fan Zongkai，Bai Keran，Chen Chao. Ultrasonic testing in the field of engineering joining[J]. The International Journal of Advanced Manufacturing Technology，2024，132(9)：4135-4160.
[3] 郭占玲，沈斌，赵志钢，等. 空气耦合超声检测复合材料研究综述[J]. 应用声学，2024，43(1)：223-236. GUO Zhanling，SHEN Bin，ZHAO Zhigang，et al. Review on air-coupled ultrasonic testing for composite materials[J]. Applied Acoustics，2024，43(1)：223-236.
[4] 周正干，冯海伟. 超声导波检测技术的研究进展[J]. 无损检测，2006，28(2)：57-63. ZHOU Zhenggan，FENG Haiwei. Progress in research of ultrasonic guided wave testing technique[J]. Nondestructive Testing，2006，28(2)：57-63.
[5] 曲志刚，武立群，安阳，等. 超声导波检测技术的发展与应用现状[J]. 天津科技大学学报，2017，32(4)：1-8. QU Zhigang，WU Liqun，AN Yang，et al. The development and application status of ultrasonic guided wave detection technology[J]. Journal of Tianjin University of Science and Technology，2017，32(4)：1-8.
[6] 何存富，郑明方，吕炎，等. 超声导波检测技术的发展、应用与挑战[J]. 仪器仪表学报，2016，37(8)：1713-1735. HE Cunfu，ZHENG Mingfang，LÜ Yan，et al. The development，application and challenges of ultrasonic guided wave detection technology[J]. Journal of Scientific Instrument，2016，37(8)：1713-1735.
[7] Honarvar F，Varvani-Farahani A. A review of ultrasonic testing applications in additive manufacturing：Defect evaluation，material characterization，and process control[J]. Ultrasonics，2020，108：106227.
[8] Cheong Y M，Kim K M，Kim D J. High-temperature ultrasonic thickness monitoring for pipe thinning in a flow-accelerated corrosion proof test facility[J]. Nuclear Engineering and Technology，2017，49(7)：1463-1471.
[9] 卢超，郭伟，石文泽，等. 高温声学检测技术的发展、应用与挑战[J]. 振动、测试与诊断，2024，44(1)：1-10. LU Chao，GUO Wei，SHI Wenze，et al. The development，application and challenges of high-temperature acoustic detection technology[J]. Journal of Vibration，Measurement & Diagnosis，2024，44(1)：1-10.
[10] 崔悦，朱丽艳，胡斌，等. 高温结构内部温度场和厚度的超声同步测量方法研究[J]. 机械工程学报，2023，59(22)：215-221. CUI Yue，ZHU Liyan，HU Bin，et al. Research on ultrasonic synchronous measurement method of internal temperature field and thickness of high-temperature structures[J]. Journal of Mechanical Engineering，2023，59(22)：215-221.
[11] Lee Y F，Lu Y. Identification of fatigue crack under vibration by nonlinear guided waves[J]. Mechanical Systems and Signal Processing，2022，163：108138.
[12] ZHENG Jianneng，HU Junchao，JIANG Yuehui，et al. High temperature effects on fatigue performance and crack initiation mechanisms of 316LN stainless steel for nuclear power pipelines[J]. Journal of Materials Research and Technology，2025，35：3281-3292.
[13] Zhang Juan，Hou Chenxue，Zhao Tlianlong，et al. 0.36BiScO₃-0.64PbTiO₃/Epoxy 1-3-2 High- temperature composite ultrasonic transducer for nondestructive testing applications[J]. IEEE Trans Ultrason Ferroelectr Freq Control，2024，71(6)：638-647.
[14] Zeng Xiaomei，Pelenovich V O，Zhang Xiangyu，et al. Response optimization of LiNbO₃ ultrasonic transducers for high temperature measurement[J]. IEEE Sensors Journal，2024，24(6)：7513-7520.
[15] Xu J，Batista C F G，Tittmann B R. Practical ultrasonic transducers for high-temperature applications using bismuth titanate and ceramabind 830[C]// 44th Annual Review of Progress in Quantitative Nondes Tructive Evaluation，volume 37，16-21 July，2017，Provo，Utah，USA. NewYork：AIP，Publishing 2018：100004.
[16] Amini M H，Sinclair A N，Coyle T W. High temperature ultrasonic transducer for real-time inspection[J]. Physics Procedia，2015，70：343-347.
[17] 赵学明. 偏铌酸铅基高温压电陶瓷的改性研究及换能器设计[D]. 成都：电子科技大学，2023. ZHAO Xueming. Research on modification of lead niobate-based high-temperature piezoelectric ceramics and design of transducers[D]. Chengdu：University of Electronic Science and Technology of China，2023.
[18] 鲜晓军，赵天龙，孙昕郝，等. BS-PT基高温压电超声换能器研究[J]. 压电与声光，2022，44(3)：431-434. XIAN Xiaojun，ZHAO Tianlong，SUN Xinhao，et al. Research on BS-PT-based high-temperature piezoelectric ultrasonic transducer[J]. Piezoelectric & Acousto-Optics，2022，44(3)：431-434.
[19] Amini M H，Sinclair A N，Coyle T W. A new high-temperature ultrasonic transducer for continuous inspection[J]. IEEE Trans. Ultrason. Ferroelectr. Freq. Control，2016，63(3)：448-55.
[20] Zheng Yang，LI Zheng，Zhou Jianjie，et al. Study on the change law of transverse ultrasonic velocity in a high temperature material[J]. Research in Nondestructive Evaluation，2020，32(1)：38-57.
[21] 付悦，李素军，陈果，等. 高温铝合金电磁超声SV波检测方法研究[J]. 传感技术学报，2023，36(3)：380-388. FU Yue，LI Sujun，CHEN Guo，et al. Research on electromagnetic ultrasonic SV wave detection method of high-temperature aluminum alloy[J]. Journal of Sensor Technology，2023，36(3)：380-388.
[22] Kwak N S，Kim J Y，Gao J C. Detection of small-flaw in carbon brake disc (C-C) using air-coupled ultrasonic C-scan technique[J]. International Journal of Precision Engineering and Manufacturing，2017，18(7)：987-994.
[23] 许鑫虎. 耐高温型空气耦合式超声换能器的优化设计[D]. 保定：河北大学，2024. XU Xinhu. Optimal design of high-temperature resistant air-coupled ultrasonic transducer[D]. Baoding：Hebei University，2024.
[24] Guo Ruipeng，Wang Haitao，Zhang Jianyan. Non-contact detection of low carbon steel using laser generated ultrasound at high temperature[J]. Optik，2017，136：536-542.
[25] 谢易微. 压电薄膜超声换能器制备及其应用研究[D]. 成都：电子科技大学，2020. XIE Yiwei. Research on the preparation and application of piezoelectric thin film ultrasonic transducer[D]. Chengdu：University of Electronic Science and Technology of China，2020.
[26] 郑凯，武兴，李俊燕，等. 高温下金属材料厚度的激光超声检测研究[J]. 机械工程学报，2021，57(10)：21-27. ZHENG Kai，WU Xing，LI Junyan，et al. Research on laser ultrasonic testing of metal material thickness at high temperature[J]. Journal of Mechanical Engineering，2021，57(10)：21-27.
[27] 马乐山，姚绍玉. 不同背衬PVDF压电薄膜超声换能器的实验研究[J]. 声学技术，1983(1)：12-14. MA Leshan，YAO Shaoyu. Experimental study on ultrasonic transducers with different backliners of PVDF piezoelectric thin films[J]. Acoustic Technology，1983(1)：12-14.
[28] 葛海燕. PVDF叉指传感器及其在食品污物检测中的应用研究[D]. 北京：北京工业大学，2006. GE Haiyan. Research on PVDF interdigital sensor and its application in food contamination detection[D]. Beijing：Beijing University of Technology，2006.
[29] 丁涛涛，朱武军，项延训，等. PVDF梳状换能器接收非线性兰姆波的实验研究[J]. 应用声学，2019，38(3)：301-306. DING Taotao，ZHU Wujun，XIANG Yanxun，et al. Experimental study on receiving nonlinear lamb waves by PVDF comb transducers[J]. Applied Acoustics，2019，38(3)：301-306.
[30] 丁涛涛，郭宇，项延训. 超声导波目标模式的激励方法研究[J]. 振动与冲击，2024，43(4)：20-26. DING Taotao，GUO Yu，XIANG Yanxun. Research on the excitation method of ultrasonic guided wave target mode[J]. Journal of Vibration and Shock，2024，43(4)：20-26.
[31] 彭钟，陈燕，袁懋诞，等. 高温压电陶瓷及高温超声换能器的研究进展[J]. 中国陶瓷，2021，57(8)：10-16. PENG Zhong，CHEN Yan，YUAN Maodan，et al. Research progress of high-temperature piezoelectric ceramics and high-temperature ultrasonic transducers[J]. China Ceramics，2021，57(8)：10-16.
[32] Jiang Xiaoning，Kim K，Zhang Shujun，et al. High-temperature piezoelectric sensing[J]. Sensors，2014，14(1)：144-169.
[33] Kazys R，Vaskeliene V. High temperature ultrasonic transducers：A review[J]. Sensors (Basel)，2021，21(9)：3200.
[34] Wong Tingyui，Tang Yu，Zou Fangxin，et al. An ultra-high accuracy temperature measurement method using acoustic waveguide[J]. IEEE Sensors Journal，2021，21(3)：2618-2626.
[35] Oh S B，Cheong Y M，Kim D J，et al. On-line monitoring of pipe wall thinning by a high temperature ultrasonic waveguide system at the flow accelerated corrosion proof facility[J]. Sensors，2019，19(8)：1762.
[36] Zaito N，Kambayashi N，Kobayashi M. High temperature performance over 700℃ of LiNbO₃-Based ultrasonic transducer[C]// 2022 IEEE International Ultrasonics Symposium (IUS). NewYork：IEEE，2022：1-4.
[37] 李瑶瑶，赵彦龙，肖宗扬，等. 压电超声换能器高温绝缘稳定性分析及改进[J]. 传感器世界，2024，30(5)：13-17. LI Yaoyao，ZHAO Yanlong，XIAO Zongyang，et al. Analysis and improvement of high-temperature insulation stability of piezoelectric ultrasonic transducers[J]. Sensor World，2024，30(5)：13-17.
[38] 吴金根，高翔宇，陈建国，等. 高温压电材料、器件与应用[J]. 物理学报，2018，67(20)：10-39. WU Jingen，GAO Xiangyu，CHEN Jianguo，et al. High-temperature piezoelectric materials，devices and applications[J]. Acta Physica Sinica，2018，67(20)：10-39.
[39] Tanwar A，Sreenivas K，Gupta V. Effect of orthorhombic distortion on dielectric and piezoelectric properties of CaBi₄Ti₄O₁₅ ceramics[J]. Journal of Applied Physics，2009，105(8)：084105.
[40] LI Fei，Zhang Shujun，Damjanovic D，et al. Local structural heterogeneity and electromechanical responses of ferroelectrics：Learning from relaxor ferroelectrics[J]. Advanced Functional Materials，2018，28(37)：1801504.
[41] 谢新春. 铋层状结构Bi₄Ti₃O₁₂基高温压电陶瓷组成设计与性能调控研究[D]. 北京：中国科学院大学，2022. XIE Xinchun. Research on composition design and performance regulation of bismuth layered structure Bi₄Ti₃O₁₂-based high-temperature piezoelectric ceramics[D]. Beijing：University of Chinese Academy of Sciences，2022.
[42] Chen Huanbei，Shen Bo，Xu Jinbao，et al. The grain size-dependent electrical properties of Bi₄Ti₃O₁₂ piezoelectric ceramics[J]. Journal of Alloys and Compounds，2013，551：92-97.
[43] Zhao Tianlong，Wang Chunming，Wang Chunlei，et al. Enhanced piezoelectric properties and excellent thermal stabilities of cobalt-modified aurivillius-type calcium bismuth titanate (CaBi₄Ti₄O₁₅)[J]. Materials Science and Engineering B-Advanced Functional Solid-State Materials，2015，201：51-56.
[44] 孙钟. 温度对超声波探伤缺陷定位、定量的影响研究[D]. 大连：大连理工大学，2009. SUN Zhong. Research on the influence of temperature on defect location and quantification in ultrasonic flaw detection[D]. Dalian：Dalian University of Technology，2009.
[45] Tai J L，Sultan M T H，Lukaszewicz A，et al. Ultrasonic velocity and attenuation of low-carbon steel at high temperatures[J]. Materials (Basel)，2023，16(14)：5123.
[46] 刘广兴，冯云国，李向前，等. 超声检测P92钢时声速、K值变化的探讨[J]. 热加工工艺，2012，41(14)：237-238. LIU Guangxing，FENG Yunguo，LI Xiangqian，et al. Discussion on the changes of sound velocity and k value during ultrasonic testing of P92 steel[J]. Hot Working Technology，2012，41(14)：237-238.
[47] 关卫和，阎长周，陈文虎，等. 高温环境下超声波横波检测技术[J]. 压力容器，2004，2：4-6. GUAN Weihe，YAN Changzhou，CHEN Wenhu，et al. Ultrasonic transverse wave detection technology in high temperature environment[J]. Pressure Vessels，2004，2：4-6.
[48] YAN Chunze，GUAN Weihe，GAO Zhanliang，et al. Ultrasonic shear wave testing of pressure vessels and pipelines under high temperature service environment[C]// ASME 2006 Pressure Vessels and Piping/ICPVT-11 Conference，July 23–27，2006，Vancouver，BC，Canada. NewYork：ASME，2008：269-272.