Numerical simulations in support of the design of an ultrasonic device for sub-assembly identification

In this paper, it is shown how numerical simulations can help designing an ultrasonic instrument operating in harsh conditions. To prevent fuel handling errors in sodium cooled fast reactors, the identification of fuel sub-assemblies using ultrasound is being investigated. It is based on the interpretation of a code (aligned notches) engraved on the sub-assembly head using an emitting/receiving ultrasonic sensor. This reading is performed in liquid sodium with high temperature (up to 600°C) transducers. A first experiment in liquid sodium demonstrated the feasibility of this method. The reading quality and robustness depend on various parameters related to the ultrasonic beam (spectral response, focal distance, focal spot size), the code geometry (especially the notches’ dimensions) and geometrical alignments. In order to avoid numerous experiments, two numerical models are developed. The first one is a finite element simulation of the sensor providing its radiated field. This model is validated with the well-known analytic solution of the Rayleigh integral; then it is applied to the sensor used in the sodium experiment. The focal distance and focal spot diameter are close to the expected values. The second simulation, using CIVA software, provides the ultrasonic scan of the code. The result is in good agreement with the sodium experiment and a first comparison with a water experiment shows that this numerical tool is relevant for easily taking into account misalignment and misorientation of the scan.