Simulation of the spatial distribution of the acoustic pressure in sonochemical reactors with numerical methods: a review

Application of ultrasound treatment in pork marination: Effects on moisture migration and microstructure

To better understanding the effects of ultrasonic marination on the porcine tissue, the moisture migration and microstructure were investigated in this study. Additionally, the acoustic field distribution was analysis using COMSOL Multiphysics. The low-filed NMR results demonstrated that ultrasonic curing induced a leftward shift in T21 and a rightward shift in T22, accompanied by a significant reduction in A22, thereby enhancing the water-holding capacity of pork. The SEM and TEM observation showed that the presence of larger interstitial gaps between muscle fibers facilitated the diffusion of NaCl. The simulation analysis revealed that the acoustic field at 26.8 kHz showed minimal standing wave effects and more pronounced cavitation, which was the main reason for the best curing effect at this frequency. The scale-up test showed the NaCl content in pork reached 1% after ultrasound curing, indicating the potential application of ultrasonic marination technology in domestic refrigerators.

Cavitation-induced particle engulfment via enhancing particle-interface interaction in solidification

Particle engulfment plays a vital role in the application of particulate reinforced metal matrix composites fabricated by ingot metallurgy. During solidification, particles are nevertheless pushed by an advancing front. As a model system, TiB2p/Al composites were used to investigate the particle engulfment facilitated by acoustic cavitation. The implosion of bubbles drives the particles plunging towards the solid/liquid interface, which increases the engulfment probability. The secondary dendrite arms are refined from 271.2 μm to 98.0 μm as a result of the forced movements of TiB2 particles. Owing to the particle engulfment and dendrite refinement, the composite with ultrasound vibration treatment shows a more rapid work-hardening rate and higher strength.

Numerical investigation of the translational motion of bubbles: The comparison of capabilities of the time-resolved and the time-averaged methods

In the present study, the accuracies of two different numerical approaches used to model the translational motion of acoustic cavitational bubble in a standing acoustic field are compared. The less accurate but less computational demanding approach is to decouple the equation of translational motion from the radial oscillation, and solve it by calculating the time-averaged forces exerted on the bubble for one acoustic cycle. The second approach is to solve the coupled ordinary differential equations directly, which provides more accurate results with higher computational effort. The investigations are carried out in the parameter space of the driving frequency, pressure amplitude and equilibrium radius. Results showed that both models are capable to reveal stable equilibrium positions; however, in the case of oscillatory solutions, the difference in terms of translational frequency may be more than three fold, and the amplitude of translational motion obtained by the time-averaged method is roughly 1.5 times higher compared to the time-resolved solution at particular sets of parameters. This observation implies that where the transient behaviour is important, the time-resolved approach is the proper choice for reliable results.

Synthesis of Ciprofloxacin-capped Gold Nanoparticles Conjugates with Enhanced Sonodynamic Antimicrobial Activity in vitro

The purpose of this article is to discuss whether gold nanoparticles (GNPs) play an auxo-action on ciprofloxacin (CIP)-mediated sonodynamic antimicrobial chemotherapy (SACT) in vitro. The measuring criterion of SACT, bactericidal efficiency, was measured by plate colony-counting methods. According to research findings, the duration of ultrasound (US) exposure, solution temperature and CIP:GNPs concentration were all critical influencing factors of SACT. Furthermore, scanning electron microscopy revealed that the group of CIP:GNPs combined with US showed the most severe damaged effect on Escherichia coli and Staphylococcus aureus, resulting in the loss of their typical microbial morphology and the disclosure of contents. Therefore, the above experimental results confirmed initially that GNPs could enhance the bacteriostasis of CIP-mediated SACT. And the intracellular reactive oxygen species (ROS) detection assays proved that this acceleration might be connected to the ROS generated through the ultrasonic mechanics. In conclusion, GNPs would be regarded as a promising auxiliary material for SACT, since they are both used to be the medication carriers and sonosensitizer accelerants.

Simulations of a full sonoreactor accounting for cavitation

In spite of the increasing interest in ultrasound processing applications, industrial scale-up remains limited, in particular by the unavailability of predictive computer tools. In this study, using a previously published model of cavitating liquids implementable as a non-linear Helmholtz equation, it is shown that a full sonoreactor can be modelled and simulated. The model includes the full transducer and the vibrations of the vessel walls, using the physics of elastic solids and piezo-electricity. The control-loop used by the generator to set the optimal frequency is also accounted for. Apart from the geometry, the unique input of the model is the current feeding the transducer whereas the dissipated electrical power, transducer complex impedance and working frequency are available as outputs. The model is put to the test against experiments realized in different geometries, varying either the input current or the transducer immersion depth. Despite the overestimation of the power dissipated in the liquid, the evolution of the acoustic load in both cases is reasonably well reproduced by simulation, which partially validates the method used.

Identification approach of acoustic cavitation via frequency spectrum of sound pressure wave signals in numerical simulation

In a sono-reactor, complex ultrasound pressure wave signal can be detected, containing multiple information related to acoustic cavitation. In this present study, acoustic cavitation in a cylinder is investigated numerically. Via Fast Fourier Transfer (FFT), the sound pressure signals from sonotrode emitting surface are separated into harmonics, sub/ultra-harmonics and cavitation white noise: (1) the appearance of harmonics proved the non-linear propagation of ultrasound, (2) at the vibratory amplitude from 5∼20μm, only harmonics exists in the frequency spectra, corresponding to expansion and compression of non-condensable gas (NCG), (3) at the vibratory amplitude range of 30∼50μm, the occurrence of sub/ultra-harmonics demonstrated gaseous cavitation occurred, and (4) at the vibratory amplitude higher than 55μm, cavitation white noise arose, pointing out the initiation of vaporous cavitation. Based on the combination of frequency spectra and cavitation zones distribution, the acoustic cavitation state in water liquid is determined.

Multi-frequency sonoreactor characterisation in the frequency domain using a semi-empirical bubbly liquid model

Recently, multi-frequency systems were reported to improve performance in power ultrasound applications. In line with this, digital prototyping of multi-frequency sonoreactors also started gaining interest. However, the conventional method of simulating multi-frequency acoustic pressure fields in the time-domain led to many challenges and limitations. In this study, a multi-frequency sonoreactor was characterised using frequency domain simulations in 2-D. The studied system consists of a hexagonal sonoreactor capable of operating at 28, 40 and 70 kHz. Four frequency combinations were studied: 28-40, 28-70, 40-70 and 28-40-70 kHz. A semi-empirical, modified Commander and Prosperetti model was used to describe the bubbly-liquid effects in the sonoreactor. The root-mean-squared acoustic pressure was compared against experimental validation results using sonochemiluminescence (SCL) images and was noted to show good qualitative agreement with SCL results in terms of antinode predictions. The empirical phase speed calculated from SCL measurements was found to be important to circumvent uncertainties in bubble parameter specifications which reduces error in the simulations. Additionally, simulation results also highlighted the importance of geometry in the context of optimising the standing wave magnitudes for each working frequency due to the effects of constructive and destructive interference.

Sonoprocessing: From Concepts to Large-Scale Reactors

Intensification of ultrasonic processes for diversified applications, including environmental remediation, extractions, food processes, and synthesis of materials, has received attention from the scientific community and industry. The mechanistic pathways involved in intensification of ultrasonic processes that include the ultrasonic generation of cavitation bubbles, radical formation upon their collapse, and the possibility of fine-tuning operating parameters for specific applications are all well documented in the literature. However, the scale-up of ultrasonic processes with large-scale sonochemical reactors for industrial applications remains a challenge. In this context, this review provides a complete overview of the current understanding of the role of operating parameters and reactor configuration on the sonochemical processes. Experimental and theoretical techniques to characterize the intensity and distribution of cavitation activity within sonoreactors are compared. Classes of laboratory and large-scale sonoreactors are reviewed, highlighting recent advances in batch and flow-through reactors. Finally, examples of large-scale sonoprocessing applications have been reviewed, discussing the major scale-up and sustainability challenges.

Numerical simulations for sonochemistry

Numerical simulations for sonochemistry are reviewed including single-bubble sonochemistry, influence of ultrasonic frequency and bubble size, acoustic field, and sonochemical synthesis of nanoparticles. The theoretical model of bubble dynamics including the effect of non-equilibrium chemical reactions inside a bubble has been validated from the study of single-bubble sonochemistry. By the numerical simulations, it has been clarified that there is an optimum bubble temperature for the production of oxidants inside an air bubble such as OH radicals and H2O2 because at higher temperature oxidants are strongly consumed inside a bubble by oxidizing nitrogen. Unsolved problems are also discussed.

Microfluidics for Multiphase Mixing and Liposomal Encapsulation of Nanobioconjugates: Passive vs. Acoustic Systems

One of the main routes to ensure that biomolecules or bioactive agents remain active as they are incorporated into products with applications in different industries is by their encapsulation. Liposomes are attractive platforms for encapsulation due to their ease of synthesis and manipulation and the potential to fuse with cell membranes when they are intended for drug delivery applications. We propose encapsulating our recently developed cell-penetrating nanobioconjugates based on magnetite interfaced with translocating proteins and peptides with the purpose of potentiating their cell internalization capabilities even further. To prepare the encapsulates (also known as magnetoliposomes (MLPs)), we introduced a low-cost microfluidic device equipped with a serpentine microchannel to favor the interaction between the liposomes and the nanobioconjugates. The encapsulation performance of the device, operated either passively or in the presence of ultrasound, was evaluated both in silico and experimentally. The in silico analysis was implemented through multiphysics simulations with the software COMSOL Multiphysics 5.5® (COMSOL Inc., Stockholm, Sweden) via both a Eulerian model and a transport of diluted species model. The encapsulation efficiency was determined experimentally, aided by spectrofluorimetry. Encapsulation efficiencies obtained experimentally and in silico approached 80% for the highest flow rate ratios (FRRs). Compared with the passive mixer, the in silico results of the device under acoustic waves led to higher discrepancies with respect to those obtained experimentally. This was attributed to the complexity of the process in such a situation. The obtained MLPs demonstrated successful encapsulation of the nanobioconjugates by both methods with a 36% reduction in size for the ones obtained in the presence of ultrasound. These findings suggest that the proposed serpentine micromixers are well suited to produce MLPs very efficiently and with homogeneous key physichochemical properties.

A Dual Frequency Ultrasonic Cleaning Tank Developed by Transient Dynamic Analysis

At present, development of manufacturer’s ultrasonic cleaning tank (UCT) to match the requirements from consumers usually relies on computer simulation based on harmonic response analysis (HRA). However, this technique can only be used with single-frequency UCT. For dual frequency, the manufacturer used information from empirical experiment alongside trial-and-error methods to develop prototypes, resulting in the UCT that may not be fully efficient. Thus, lack of such a proper calculational method to develop the dual frequency UCT was a problem that greatly impacted the manufacturers and consumers. To resolve this problem, we proposed a new model of simulation using transient dynamics analysis (TDA) which was successfully applied to develop the prototype of dual frequency UCT, 400 W, 18 L in capacity, eight horn transducers, 28 and 40 kHz frequencies for manufacturing. The TDA can indicate the acoustic pressure at all positions inside the UCT in transient states from the start to the states ready for proper cleaning. The calculation also reveals the correlation between the positions of acoustic pressure and the placement positions of transducers and frequencies. In comparison with the HRA at 28 kHz UCT, this TDA yielded the results more accurately than the HRA simulation, comparing to the experiments. Furthermore, the TDA can also be applied to the multifrequency UCTs as well. In this article, the step-by-step development of methodology was reported. Finally, this simulation can lead to the successful design of the high-performance dual frequencies UCT for the manufacturers.

3D flow simulations and pressure measurements for the evaluation of cavitation dynamics and flow aggressiveness in ultrasonic erosion devices with varying gap widths

Cavitation induced wall loads at an ultrasonic horn facility are analyzed by 3D flow simulations and temporally high-resolved pressure measurements for varying gap widths between horn and stationary erosion specimen. Piezoelectric polyvinylidene fluoride (PVDF) probes are placed at different radial wall positions at the stationary specimen opposite of the oscillation horn and yield a declining flow aggressiveness with increasing radial position and gap width. The measurement results are reproduced by virtual probes in CFD simulations. Pressure measurement results yield a measure of flow aggressiveness in terms of wall load collectives that correlate well with incubation times obtained by erosion tests. A maximum aggressiveness at the specimen at 0.5mm gap width is obtained. Subharmonic frequencies associated with horn-attached void cavities increase with gap width which is well captured by the simulation. Due to the revealing of 3D flow patterns by the validated CFD results, detailed flow mechanisms associated with flow aggressiveness are discussed. The subharmonic frequency characteristics vs. gap width is associated with the shielding of the inner attached cavity region for small gaps and prevents the cavity from subharmonic collapse for several horn cycles. This shielding is less pronounced for larger gaps and leads to a shorter life time of the attached cavity and therefore to higher subharmonic frequencies.

A strict formulation of a nonlinear Helmholtz equation for the propagation of sound in bubbly liquids. Part II: Application to ultrasonic cavitation

This paper addresses one of the greatest challenges in sonochemistry that has impaired scaling up ultrasonic processes, which is the lack of models capable of predicting the pressure distribution in sonoreactors. This work studies the effect of acoustic pressure on the transmission of sound thought cavitating bubbly liquids by utilizing the nonlinear Helmholtz equation that was demonstrated on the paper part I. The model showed that the wave number and the attenuation can be estimated from the bubble dynamics of inertial bubbles and the local bubble density. The linear model of Commander and Prosperetti is encompassed by the nonlinear model. The model was employed to predict the pressure distribution below an ultrasonic horn tip achieving a relatively close prediction of the experimental data and certainly an accurate qualitative description of the distribution of the pressure field in spite of the simplifications of the model and the assumptions of unknown variables such as the bubble density, bubble distribution and the vessel boundary conditions.

Numerical simulations of stable cavitation bubble generation and primary Bjerknes forces in a three-dimensional nonlinear phased array focused ultrasound field

We present a model developed for studying the generation of stable cavitation bubbles and their motion in a three-dimensional volume of liquid with axial symmetry under the effect of finite-amplitude phased array focused ultrasound. The density of bubbles per unit volume is determined by a nonlinear law which is a threshold-dependent function of the negative acoustic pressure reached in the liquid, in which nuclei are initially distributed. The nonlinear mutual interaction of ultrasound and bubble oscillations is modeled by a nonlinear coupled differential system formed by the wave and a Rayleigh-Plesset equations, for which both the pressure and the bubble oscillation variables are unknown. The system, which accounts for nonlinearity, dispersion, and attenuation due to the bubbles, is solved by numerical approximations. The nonlinear acoustic pressure field is then used to evaluate the primary Bjerknes force field and to predict the subsequent motion of bubbles. In order to illustrate the procedure, a medium-high and a low ultrasonic frequency configurations are assumed. Simulation results show where bubbles are generated, the nonlinear effects they have on ultrasound, and where they are relocated. Despite many physical restrictions and thanks to its particularities (two nonlinear coupled fields, bubble generation, bubble motion), the numerical model used in this work gives results that show qualitative coherence with data observed experimentally in the framework of stable cavitation and suggest their usefulness in some application contexts.

Numerical Modelling of the Ultrasonic Treatment of Aluminium Melts: An Overview of Recent Advances

The prediction of the acoustic pressure field and associated streaming is of paramount importance to ultrasonic melt processing. Hence, the last decade has witnessed the emergence of various numerical models for predicting acoustic pressures and velocity fields in liquid metals subject to ultrasonic excitation at large amplitudes. This paper summarizes recent research, arguably the state of the art, and suggests best practice guidelines in acoustic cavitation modelling as applied to aluminium melts. We also present the remaining challenges that are to be addressed to pave the way for a reliable and complete working numerical package that can assist in scaling up this promising technology.

Enabling low power acoustics for capillary sonoreactors

Capillary reactors demonstrate outstanding potential for on-demand flow chemistry applications. However, non-uniform distribution of multiphase flows, poor solid handling, and the risk of clogging limit their usability for continuous manufacturing. While ultrasonic irradiation has been traditionally applied to address some of these limitations, their acoustic efficiency, uniformity and scalability to larger reactor systems are often disregarded. In this work, high-speed microscopic imaging reveals how cavitation-free ultrasound can unclog and prevent the blockage of capillary reactors. Modeling techniques are then adapted from traditional acoustic designs and applied to simulate and prototype sonoreactors with wider and more uniform sonication areas. Blade-, block- and cylindrical shape sonotrodes are optimized to accommodate longer capillary lengths in sonoreactors resonating at 28 kHz. Finally, a novel helicoidal capillary sonoreactor is proposed to potentially deal with a high concentration of solid particles in miniaturized flow chemistry. The acoustic designs and first principle rationalization presented here offer a transformative step forward in the scale-up of efficient capillary sonoreactors.

Numerical investigation of design parameters for optimization of the in-situ ultrasonic fouling removal technique for pipelines

Fouling build-up in engineering assets is a known problem and, as a solution, the application of power ultrasonic for in-situ fouling removal has gained much attention from the industry. Current state-of-the-art fouling removal includes the use of hydraulic, chemical and manual techniques. Much research has been conducted to advance the knowledge on the potential uses of ultrasonics across different fouling applications, primarily in reverse osmosis membranes and heat exchangers. However, the optimization of in-situ ultrasonic fouling removal has not yet been investigated and is still in its infancy. The present study uses a previously experimentally-validated numerical model to conduct a parametric study in order to optimize the technique. Focus was given to the adoption of ultrasonics for large diameter pipes. Therefore, this investigation was conducted on a 6 in. schedule 40-carbon steel pipe. Parameters investigated include: optimum number of transducers to remove fouling in long pipes from a single transducer location; performance at elevated temperature; different fluid domains; optimum voltage; variety of input signals and incremental thickness of fouling. Depending on the particular studied conditions, the possible fouling removal of up to +/-3 m from a single transducer location is demonstrated in a 6 in. schedule 40 carbon steel pipe.

Ultrasonic liquid metal processing: The essential role of cavitation bubbles in controlling acoustic streaming

The acoustic streaming behaviour below an ultrasonic sonotrode in water was predicted by numerical simulation and validated by experimental studies. The flow was calculated by solving the transient Reynolds-Averaged Navier-Stokes equations with a source term representing ultrasonic excitation implemented from the predictions of a nonlinear acoustic model. Comparisons with the measured flow field from Particle Image Velocimetry (PIV) water experiments revealed good agreement in both velocity magnitude and direction at two power settings, supporting the validity of the model for acoustic streaming in the presence of cavitating bubbles. Turbulent features measured by PIV were also recovered by the model. The model was then applied to the technologically important area of ultrasonic treatment of liquid aluminium, to achieve the prediction of acoustic streaming for the very first time that accounts for nonlinear pressure propagation in the presence of acoustic cavitation in the melt. Simulations show a strong dependence of the acoustic streaming flow direction on the cavitating bubble volume fraction, reflecting PIV observations. This has implications for the technological use of ultrasound in liquid metal processing.

Low-intensity ultrasound induced cavitation and streaming in oxygen-supersaturated water: Role of cavitation bubbles as physical cleaning agents

A number of acoustic and fluid-dynamic phenomena appear in ultrasonic cleaning baths and contribute to physical cleaning of immersed surfaces. Propagation and repeated reflection of ultrasound within cleaning baths build standing-wave-like acoustic fields; when an ultrasound intensity gradient appears in the acoustic fields, it can in principle induce steady streaming flow. When the ultrasound intensity is sufficiently large, cavitation occurs and oscillating cavitation bubbles are either trapped in the acoustic fields or advected in the flow. These phenomena are believed to produce mechanical action to remove contaminant particles attached at material surfaces. Recent studies suggest that the mechanical action of cavitation bubbles is the dominant factor of particle removal in ultrasonic cleaning, but the bubble collapse resulting from high-intensity ultrasound may be violent enough to give rise to surface erosion. In this paper, we aim to carefully examine the role of cavitation bubbles from ultrasonic cleaning tests with varying dissolved gas concentration in water. In our cleaning tests using 28-kHz ultrasound, oxygen-supersaturated water is produced by oxygen-microbubble aeration and used as a cleaning solution, and glass slides spin-coated with silica particles of micron/submicron sizes are used to define cleaning efficiency. High-speed camera recordings and Particle Image Velocimetry analysis with a pressure oscillation amplitude of 1.4 atm at the pressure antinode show that the population of cavitation bubbles increases and streaming flow inside the bath is promoted, as the dissolved oxygen supersaturation increases. The particle removal is found to be achieved mainly by the action of cavitation bubbles, but there exists optimal gas supersaturation to maximize the removal efficiency. Our finding suggests that low-intensity ultrasound irradiation under the optimal gas supersaturation in cleaning solutions allows for having mild bubble dynamics without violent collapse and thus cleaning surfaces without cavitation erosion. Finally, observations of individual bubble dynamics and the resulting particle removal are reported to further support the role of cavitation bubbles as cleaning agents.

Fundamental studies of ultrasonic melt processing

Ultrasonic (cavitation) melt processing attracts considerable interest from both academic and industrial communities as a promising route to provide clean, environment friendly and energy efficient solutions for some of the core issues of the metal casting industry, such as improving melt quality and providing structure refinement. In the last 5 years, the authors undertook an extensive research programme into fundamental mechanisms of cavitation melt processing using state-of-the-art and unique facilities and methodologies. This overview summarises the recent results on the evaluation of acoustic pressure and melt flows in the treated melt, direct observations and quantitative analysis of cavitation in liquid aluminium alloys, in-situ and ex-situ studies of the nucleation, growth and fragmentation of intermetallics, and de-agglomeration of particles. These results provide valuable new insights and knowledge that are essential for upscaling ultrasonic melt processing to industrial level.

Depth effect on the inertial collapse of cavitation bubble under ultrasound: Special emphasis on the role of the wave attenuation

Acoustic cavitation concentrates and releases a very large amount of energy in localized areas, which can be used for many physical and chemical processes. Even though acoustic cavitation has been studied widely for decades in lab-scale sonoreactors, only few studies have been devoted to characterize this event in big-scale sonoreactors, where the liquid depth may have a critical influence on the bubble collapse. The present computational study furnished numerical data about the effect of depth (z = 0-10 m) on acoustic cavitation with special focus on the role of attenuation of the ultrasound wave on the dramatic conditions developed within bubbles at collapse. The used mathematical model takes into account the liquid compressibility, surface tension and viscosity, depth as well as the attenuation of the ultrasound wave with depth. It was found that the maximum bubble temperature (T_max) and pressure (p_max) at the collapse diminished considerably with deepening into water up to 10 m with a considerable contribution of the ultrasound wave attenuation in the overall reduction event. The reduction in T_max and p_max with depth was more pronounced at higher frequency (1000 kHz) and lower temperature (10 °C) in which losses of about up to 72% in T_max and till 94% in p_max (as compared with values at z = 0) were obtained at z = 10 m. Depending on operating conditions, i.e. frequency, acoustic intensity or liquid temperature, the ultrasound wave attenuation may contribute with up to 47% and 79% in the overall reductive effect of depth toward T_max and p_max, respectively. These results were discussed, interpreted and used to support some available experimental observations. Finally, the results of the present study may help in designing large-scale sonoreactors through providing data about the effect of one of the missing links between lab-scale sonoreactors and industrial large-scale sonoreactors.

Measurement of distribution of broadband noise and sound pressures in sonochemical reactor

Cross-sectional area distribution of broadband noise in a sonochemical reactor was measured to estimate reaction fields. A needle-type hydrophone scanned the sonochemical reactor in horizontal and vertical directions at one-millimeter interval. To show an absolute value of broadband noise, average of broadband sound pressure was defined. The distribution of sound pressures at the fundamental and second harmonic frequencies were also measured. In the case of driving frequency at 130 kHz, sonochemical reaction fields were observed in several ellipse shapes. The reaction fields in upper part of the reactor was high because cavitation bubbles moved upper part due to radiation force. The sound pressure distribution at the fundamental frequency showed existence of standing wave and reaction fields were weak at pressure antinode because cavitation bubbles were repelled by primary Bjerknes force. The sound pressure distribution at the second harmonic frequency indicated that the pattern of bubbles distribution resembled to that of reaction fields closely. In the case at 43 kHz, distributions of reaction fields and sound pressures were complex due to coupled vibration. The reaction fields were relatively weak in areas which had very high sound pressures at the fundamental frequency.

The cavitation erosion of ultrasonic sonotrode during large-scale metallic casting: Experiment and simulation

Ultrasonic sonotrodes play an essential role in transmitting power ultrasound into the large-scale metallic casting. However, cavitation erosion considerably impairs the in-service performance of ultrasonic sonotrodes, leading to marginal microstructural refinement. In this work, the cavitation erosion behaviour of ultrasonic sonotrodes in large-scale castings was explored using the industry-level experiments of Al alloy cylindrical ingots (i.e. 630 mm in diameter and 6000 mm in length). When introducing power ultrasound, severe cavitation erosion was found to reproducibly occur at some specific positions on ultrasonic sonotrodes. However, there is no cavitation erosion present on the ultrasonic sonotrodes that were not driven by electric generator. Vibratory examination showed cavitation erosion depended on the vibration state of ultrasonic sonotrodes. Moreover, a finite element (FE) model was developed to simulate the evolution and distribution of acoustic pressure in 3-D solidification volume. FE simulation results confirmed that significant dynamic interaction between sonotrodes and melts only happened at some specific positions corresponding to severe cavitation erosion. This work will allow for developing more advanced ultrasonic sonotrodes with better cavitation erosion-resistance, in particular for large-scale castings, from the perspectives of ultrasonic physics and mechanical design.

Influence of sound directions on acoustic field characteristics within a rectangle-shaped sonoreactor: Numerical simulation and experimental study

Acoustic field intensity and distribution are the most important factors for the efficiency of ultrasonic processing. Recent simulation studies suggested that sound direction could influence both acoustic field intensity and distribution, but this influence has scarcely been investigated experimentally so far. In this work, we systematically studied the influence of sound directions on the acoustic field with up to five directions via both simulation and experiment. Fluid-structure interaction (FSI) harmonic response simulation and aluminum foil erosion experiment were employed to study the acoustic field under different directional combinations of ultrasonic sources. Results of simulation coincided well with that of experiment, which indicated that acoustic intensity, uniformity and cavitation characteristics were significantly affected by sound directions. Based on the results, several influence rules of sound directions were proposed. Optimal acoustic field with sound intensity of 30 times higher than that of single-wall excitation and severe cavitation volume of 95% was obtained. This work provides useful guidelines for acoustic field design of high-intensity ultrasonic apparatus.

Experimental and numerical investigation of acoustic pressures in different liquids

In an attempt to quantify the instantaneous pressure field in cavitating liquids at large forcing signals, pressures were measured in four different liquids contained in vessels with a frequency mode in resonance with the forcing signal. The pressure field in liquid metal was quantified for the first time, with maximum pressures of the order of 10-15 MPa measured in liquid aluminium. These high pressures are presumed to be responsible for deagglomeration and fragmentation of dendritic intermetallics and other inclusions. Numerical modelling showed that acoustic shielding attenuates pressure far from the sonotrode and it is prominent in the transparent liquids studied but less so in aluminium, suggesting that aluminium behaviour is different. Due to acoustic shielding, the numerical model presented cannot adequately capture the pressure field away from the intense cavitation zone, but gives a good qualitative description of the cavitation activity. The results obtained contribute to understanding the process of ultrasonic melt treatment (UST) of metal alloys, while facilitating further the guidelines formulation and reproducible protocols for controlling UST at industrial levels.

Process intensification

Process intensification (PI) is a rapidly growing field of research and industrial development that has already created many innovations in chemical process industry. PI is directed toward substantially smaller, cleaner, more energy-efficient technology. Furthermore, PI aims at safer and sustainable technological developments. Its tools are reduction of the number of devices (integration of several functionalities in one apparatus), improving heat and mass transfer by advanced mixing technologies and shorter diffusion pathways, miniaturization, novel energy techniques, new separation approaches, integrated optimization and control strategies. This review discusses many of the recent developments in PI. Starting from fundamental definitions, microfluidic technology, mixing, modern distillation techniques, membrane separation, continuous chromatography, and application of gravitational, electric, and magnetic fields will be described.

Numerical models for the study of the nonlinear frequency mixing in two and three-dimensional resonant cavities filled with a bubbly liquid

The objective of this work is to develop versatile numerical models to study the nonlinear distortion of ultrasounds and the generation of low-ultrasonic frequency signals by nonlinear frequency mixing in two and three-dimensional resonators filled with bubbly liquids. The interaction of the acoustic field and the bubble vibrations is modeled through a coupled differential system formed by the multi-dimensional wave equation and a Rayleigh-Plesset equation. The numerical models we develop are based on multi-dimensional finite-volume techniques and a time discretization carried out by finite differences. Numerical experiments are performed for complex modes in many different cavities considering different kinds of boundary conditions and taking advantage of the dispersive character of the bubbly fluid to match specific resonances of the cavities. Results show the distribution of fundamental and harmonics for single frequency excitation and difference-frequency component for two-frequency excitation that are promoted by the strong nonlinearity of the bubbly medium. The numerous simulations analyzed suggest that the new numerical models developed and proposed in this paper are useful to understand the behavior of ultrasounds in bubbly liquids for sonochemical processes and applications of nonlinear frequency mixing.

Numerical modelling of ultrasonic waves in a bubbly Newtonian liquid using a high-order acoustic cavitation model

To address difficulties in treating large volumes of liquid metal with ultrasound, a fundamental study of acoustic cavitation in liquid aluminium, expressed in an experimentally validated numerical model, is presented in this paper. To improve the understanding of the cavitation process, a non-linear acoustic model is validated against reference water pressure measurements from acoustic waves produced by an immersed horn. A high-order method is used to discretize the wave equation in both space and time. These discretized equations are coupled to the Rayleigh-Plesset equation using two different time scales to couple the bubble and flow scales, resulting in a stable, fast, and reasonably accurate method for the prediction of acoustic pressures in cavitating liquids. This method is then applied to the context of treatment of liquid aluminium, where it predicts that the most intense cavitation activity is localised below the vibrating horn and estimates the acoustic decay below the sonotrode with reasonable qualitative agreement with experimental data.

Experimental study on the influence of low-frequency and low-intensity ultrasound on the permeability of the Mycobacterium smegmatis cytoderm and potentiation with levofloxacin

Tuberculosis is an infectious disease caused by the bacterium M. tuberculosis. The aim of this study was to investigate the bactericidal effect and underlying mechanisms of low-frequency and low-intensity ultrasound combined with levofloxacin treatment against M. smegmatis (a surrogate of M. tuberculosis). As part of this study, M. smegmatis was continuously irradiated with low frequency ultrasound (42kHz) using several different doses whereby both intensity (0.138, 0.190 and 0.329W/cm²) and exposure time (5, 15 and 20min) were varied. Flow cytometric analyses revealed that the permeability of M. smegmatis increased following ultrasound exposure. The survival rate, structure and morphology of bacteria in the lower-dose (I_SATA=0.138W/cm² for 5min) ultrasound group displayed no significant differences upon comparison with the untreated group. However, the survival rate of bacteria was significantly reduced and the bacterial structure was damaged in the higher-dose (I_SATA=0.329W/cm² for 20min) ultrasound group. Ultrasound irradiation (0.138W/cm²) was subsequently applied to M. smegmatis in combination with levofloxacin treatment for 5min. The results demonstrated that the bactericidal effect of ultrasonic irradiation combined with levofloxacin is higher compared to ultrasound alone or levofloxacin alone.

Comparison of sonochemiluminescence images using image analysis techniques and identification of acoustic pressure fields via simulation

One common method to determine the existence of cavitational activity in power ultrasonics systems is by capturing images of sonoluminescence (SL) or sonochemiluminescence (SCL) in a dark environment. Conventionally, the light emitted from SL or SCL was detected based on the number of photons. Though this method is effective, it could not identify the sonochemical zones of an ultrasonic systems. SL/SCL images, on the other hand, enable identification of 'active' sonochemical zones. However, these images often provide just qualitative data as the harvesting of light intensity data from the images is tedious and require high resolution images. In this work, we propose a new image analysis technique using pseudo-colouring images to quantify the SCL zones based on the intensities of the SCL images and followed by comparison of the active SCL zones with COMSOL simulated acoustic pressure zones.

CFD study of the flow pattern in an ultrasonic horn reactor: Introducing a realistic vibrating boundary condition

Recently, great attention has been paid to predict the acoustic streaming field distribution inside the sonoreactors, induced by high-power ultrasonic wave generator. The focus of this paper is to model an ultrasonic vibrating horn and study the induced flow pattern with a newly developed moving boundary condition. The numerical simulation utilizes the modified cavitation model along with the "mixture" model for turbulent flow (RNG, k-ε), and a moving boundary condition with an oscillating parabolic-logarithmic profile, applied to the horn tip. This moving-boundary provides the situation in which the center of the horn tip vibrates stronger than that of the peripheral regions. The velocity field obtained by computational fluid dynamic was in a reasonably good agreement with the PIV results. The moving boundary model is more accurate since it better approximates the movement of the horn tip in the ultrasonic assisted process. From an optimizing point of view, the model with the new moving boundary is more suitable than the conventional models for design purposes because the displacement magnitude of the horn tip is the only fitting parameter. After developing and validating the numerical model, the model was utilized to predict various quantities such as cavitation zone, pressure field and stream function that are not experimentally feasible to measure.

A numerical simulation of acoustic field within liquids subject to three orthogonal ultrasounds

When one beam of ultrasound propagates along a single direction in liquids, the cavitation effect is always confined to a limited volume close to the ultrasonic source. This greatly limits the application of power ultrasound in liquid processing and materials fabrication. In this study, a methodology for applying three orthogonal ultrasounds within liquids has been proposed. By solving the Helmholtz equation, the sound field distribution characteristics are investigated in 1D (one dimensional), 2D (two dimensional) and 3D (three dimensional) ultrasounds at their resonant frequencies, which show that the coherent interaction of three beams of ultrasounds is able to strikingly promote the sound pressure level and reinforce the mean acoustic energy density as compared with that in 1D case. Hence, the potential cavitation volume is enlarged remarkably. This opens new possibilities for the design and optimization of ultrasonic technology in fabricating materials.

A numerical model for the study of the difference frequency generated from nonlinear mixing of standing ultrasonic waves in bubbly liquids

The aim of this paper is the study of the behavior of nonlinear standing ultrasonic waves in bubbly liquids and the generation of the difference frequency by nonlinear mixing of several signals. To this end we present a new numerical model based on the finite-volume method and the finite-difference method. This model solves the differential system formed by the wave equation and a Rayleigh-Plesset equation coupling the acoustic pressure field with the bubble vibrations. We consider a resonator filled with a bubbly liquid excited by an ultrasonic pressure source. The numerical experiments presented here are performed by modifying the source amplitude and frequency, the void fraction in the liquid, as well as the length of the resonator. The results allow us to observe the physical effects due to the presence of the bubbles in the liquid: nonlinearity, dispersion, attenuation. The nonlinear frequency mixing performed in the resonator is also evidenced. The amplitude of the generated difference frequency is studied as a function of the pressure amplitude and for several primary frequencies. Our results suggest that a better response is obtained for primary frequencies situated below the bubble resonance. They show a very high difference-frequency amplitude response for a cavity resonant at one wavelength of the difference frequency in the bubbly medium. This analyze could be useful for some practical applications.

Particle size studies to reveal crystallization mechanisms of the metal organic framework HKUST-1 during sonochemical synthesis

Systematic studies of key operating parameters for the sonochemical synthesis of the metal organic framework (MOF) HKUST-1(also called CuBTC) were performed including reaction time, reactor volume, sonication amplitude, sonication tip size, solvent composition, and reactant concentrations analyzed through SEM particle size analysis. Trends in the particle size and size distributions show reproducible control of average particle sizes between 1 and 4μm. These results along with complementary studies in sonofragmentation and temperature control were conducted to compare these results to kinetic crystal growth models found in literature to develop a plausible hypothetical mechanism for ultrasound-assisted growth of metal-organic-frameworks composed of a competitive mechanism including constructive solid-on-solid (SOS) crystal growth and a deconstructive sonofragmentation.

The effects of ultrasound on micromixing

The Villermaux-Dushman reaction is a widely used technique to study micromixing efficiencies with and without sonication. This paper shows that ultrasound can interfere with this reaction by sonolysis of potassium iodide, which is excessively available in the Villermaux-Dushman solution, into triiodide ions. Some corrective actions, to minimize this interference, are proposed. Furthermore, the effect of ultrasonic frequency, power dissipation, probe tip surface area and stirring speed on micromixing were investigated. The power and frequency seem to have a significant impact on micromixing in contrast to the stirring speed and probe tip surface area. Best micromixing was observed with a 24kHz probe and high power intensities. Experiments with different frequencies but a constant power intensity, emitter surface, stirring speed, cavitation bubble type and reactor design showed best micromixing for the highest frequency of 1135kHz. Finally, these results were used to test the power law model of Rahimi et al. This model was not able to predict micromixing accurately and the addition of the frequency, as an additional parameter, was needed to improve the simulations.

A two-dimensional nonlinear model for the generation of stable cavitation bubbles

Bubbles appear by acoustic cavitation in a liquid when rarefaction pressures attain a specific threshold value in a liquid. Once they are created, the stable cavitation bubbles oscillate nonlinearly and affect the ultrasonic field. Here we present a model developed for the study of bubble generation in a liquid contained in a two-dimensional cavity in which a standing ultrasonic field is established. The model considers dissipation and dispersion due to the bubbles. It also assumes that both the ultrasonic field and the bubble oscillations are nonlinear. The numerical experiments predict where the bubbles are generated from a population of nuclei distributed in the liquid and show how they affect the ultrasonic field.

Numerical simulation of the nonlinear ultrasonic pressure wave propagation in a cavitating bubbly liquid inside a sonochemical reactor

We investigate the acoustic wave propagation in bubbly liquid inside a pilot sonochemical reactor which aims to produce antibacterial medical textile fabrics by coating the textile with ZnO or CuO nanoparticles. Computational models on acoustic propagation are developed in order to aid the design procedures. The acoustic pressure wave propagation in the sonoreactor is simulated by solving the Helmholtz equation using a meshless numerical method. The paper implements both the state-of-the-art linear model and a nonlinear wave propagation model recently introduced by Louisnard (2012), and presents a novel iterative solution procedure for the nonlinear propagation model which can be implemented using any numerical method and/or programming tool. Comparative results regarding both the linear and the nonlinear wave propagation are shown. Effects of bubble size distribution and bubble volume fraction on the acoustic wave propagation are discussed in detail. The simulations demonstrate that the nonlinear model successfully captures the realistic spatial distribution of the cavitation zones and the associated acoustic pressure amplitudes.

Prediction of the acoustic and bubble fields in insonified freeze-drying vials

The acoustic field and the location of cavitation bubble are computed in vials used for freeze-drying, insonified from the bottom by a vibrating plate. The calculations rely on a nonlinear model of sound propagation in a cavitating liquid [Louisnard, Ultrason. Sonochem., 19, (2012) 56-65]. Both the vibration amplitude and the liquid level in the vial are parametrically varied. For low liquid levels, a threshold amplitude is required to form a cavitation zone at the bottom of the vial. For increasing vibration amplitudes, the bubble field slightly thickens but remains at the vial bottom, and the acoustic field saturates, which cannot be captured by linear acoustics. On the other hand, increasing the liquid level may promote the formation of a secondary bubble structure near the glass wall, a few centimeters below the free liquid surface. These predictions suggest that rather complex acoustic fields and bubble structures can arise even in such small volumes. As the acoustic and bubble fields govern ice nucleation during the freezing step, the final crystal's size distribution in the frozen product may crucially depend on the liquid level in the vial.

A review on textile sonoprocessing: a special focus on sonosynthesis of nanomaterials on textile substrates

The chemical and physical effects of ultrasound with a frequency above 16kHz, higher than the audible frequency of the human ear, have proven to be a useful tool for variety of systems ranging from the application of ultrasound in environmental remediation to the cooperation of ultrasound waves with chemical processing regarding as sonochemistry. Ultrasound opened up new advances in textile wet processing including desizing, scouring, bleaching, dyeing, printing and finishing and also nanoprocessing including nanopretreatment, nanodyeing, nanoprinting and nanofinishing. Use of ultrasound appears to be a promising alternative technique to reduce energy, chemicals and time involved in various operations. Over the past years there has been an enormous effort on using sonochemistry for the synthesis of nanomaterials on various textile materials. In situ sonosynthesis of nanoparticles and nanocomposites on different textiles is a pioneering approach driving future investigations. With such wide range of applications and vast ever increasing publications, the objective of this paper is presenting a comprehensive review on ultrasound application in textile from early time to now by the main emphasis on the sonosynthesis of nanomaterials outlining directions toward future research.

Significance of Ultrasonic Cavitation Field Distribution in Microcellular Foaming of Polymers

In this study, the influence of field distribution of ultrasonic waves on the manufacturing of microcellular Acrylonitrile-Butadiene-Styrene (ABS) foam was investigated. In the primary studies, Aluminum foil erosion tests were performed to analyze the spatial field distribution of ultrasonic waves throughout the water bath. It was found that there exists a critical effective distance from the ultrasonic transducer where the maximum cavitation intensity can be achieved. Prior to and beyond this critical effective distance, the cavitation intensity reduces drastically. In the succeeding study, gas saturated polymer pellets were placed inside the ultrasound medium at various effective distances from the transducer for a predefined amount of treatment time and then were microcellular solid-state batch foamed. Intense cell nucleation phenomenon was observed in samples sonicated at the critical effective distance, while at other distances a very mild increment in cell density was observed. The expansion ratio and cell morphology was also found to be significantly affected by the relative placement of gas-saturated polymer with respect to the transducer in sonication medium.