Wave propagation visualization in an experimental model for a control rod drive mechanism assembly

Abstract Nondestructive inspection techniques such as ultrasonic testing, eddy current testing, and visual testing are being developed to detect primary water stress corrosion cracks in control rod drive mechanism (CRDM) assemblies of nuclear power plants. A unit CRDM assembly consists of a reactor upper head including cladding, a penetration nozzle, and J-groove dissimilar metal welds with buttering. In this study, we fabricated a full-scale CRDM assembly mock-up. An ultrasonic propagation imaging (UPI) method using a scanning laser ultrasonic generator is proposed to visualize and simulate ultrasonic wave propagation around the thick and complex CRDM assembly. First, the proposed laser UPI system was validated for a simple aluminium plate by comparing the ultrasonic wave propagation movie (UWPM) obtained using the system with numerical simulation results reported in the literature. Lamb wave mode identification and damage detectability, depending on the ultrasonic frequency, were also included in the UWPM analysis. A CRDM assembly mock-up was fabricated in full-size and its vertical cross section was scanned using the laser UPI system to investigate the propagation characteristics of the longitudinal and Rayleigh waves in the complex structure. The ultrasonic source location and frequency were easily simulated by changing the sensor location and the band pass filtering zone, respectively. The ultrasonic propagation patterns before and after cracks in the weld and nozzle of the CRDM assembly were also analyzed. Since this visualization method is not limited in the flat cross section, it will be useful in developing ultrasound-based structural health monitoring technologies, advanced nondestructive methods, and numerical models. In addition, the proposed laser UPI system could be a useful tool in optimizing the receiver and transmitter locations, the ultrasonic path, and the ultrasonic frequency.