Enhancing signal to noise ratio by fine-tuning tapers of cladded/uncladded buffer rods in ultrasonic time domain reflectometry in smelters

Buffer rods (BR) as waveguides in ultrasonic time domain reflectometry (TDR) can somewhat extend the range of industrial applications of ultrasonics. Level, temperature and flow measurements involving elevated temperatures, corrosive fluids and generally harsh environments are some of the applications in which conventional ultrasonic transducers cannot be used directly in contact with the media. In such cases, BRs with some design modifications can make ultrasonic TDR measurements possible with limited success. This paper deals with TDR in conjunction with distance measurements in extremely hot fluids, using conventional ultrasonic transducers in combination with BRs. When using BRs in the ultrasonic measurement systems in extreme temperatures, problems associated with size and the material of the buffer, have to be addressed. The resonant frequency of the transducer and the relative size of the transducer with respect to the diameter of BR are also important parameters influencing the signal to noise ratio (SNR) of the signal processing system used in the ultrasonic TDR. This paper gives an overview of design aspects related to the BRs with special emphasis on tapers and cladding used on BRs. As protective cladding, zirconium oxide–yttrium oxide composite was used, with its proven thermal stability in withstanding temperatures in rocket and jet engines up to 1650 °C. In general a BR should guide the signals through to the medium and from and back to the transducer without excessive attenuation and at the same time not exacerbate the noise in the measurement system. The SNR is the decisive performance indicator to consider in the design of BR based ultrasonic TDR, along with appropriate transducer, with suitable size and operating frequency. This work presents and analyses results from extensive experiments related to fine-tuning both geometry of and signals in cladded/uncladded BRs used in high temperature ultrasonic TDR with focus on overall performance based on measured values of SNR.