Experimental and numerical investigation of acoustic pressures in different liquids

Cavitation-induced shock wave behaviour in different liquids

This paper follows our earlier work where a strong high frequency pressure peak has been observed as a consequence of the formation of shock waves due to the collapse of cavitation bubbles in water, excited by an ultrasonic source at 24 kHz. We study here the effects of liquid physical properties on the shock wave characteristics by replacing water as the medium successively with ethanol, glycerol and finally a 1:1 ethanol-water solution. The pressure frequency spectra obtained in our experiments (from more than 1.5 million cavitation collapsing events) show that the expected prominent shockwave pressure peak was barely detected for ethanol and glycerol, particularly at low input powers, but was consistently observed for the 1:1 ethanol-water solution as well as in water, with a slight shift in peak frequency for the solution. We also report two distinct features of shock waves in raising the frequency peak at MHz (inherent) and contributing to the raising of sub-harmonics (periodic). Empirically constructed acoustic pressure maps revealed significantly higher overall pressure amplitudes for the ethanol-water solution than for other liquids. Furthermore, a qualitative analysis revealed that mist-like patterns are developed in ethanol-water solution leading to higher pressures.

Mechanical destruction using a minimally invasive Ultrasound Needle induces anti-tumor immune responses and synergizes with the anti-PD-L1 blockade

Immune checkpoint inhibitors (ICIs) have been widely used in treating various tumors; however, the objective response rate of ICIs is less than 40%. In this study, we attempted to induce anti-tumor immune responses using an improved ultrasonic horn device, Ultrasound Needle (UN). We tested its synergistic anti-tumor efficacy with an anti-PD-L1 antibody in a mouse tumor model. Under different parameters, UN treatment selectively induced mechanical destruction and thermal ablation effects on tumor tissues. The mechanical destruction effect of UN treatment increased the infiltration of CD8⁺ T cells in tumors and relieved the immunosuppressive tumor microenvironment. It also induced systemic anti-tumor immune responses and enhanced the therapeutic efficacy of the anti-PD-L1 antibody in both local and abscopal tumors. The mechanical destruction effect of UN treatment resulted in the release of damage-associated molecular patterns and promoted dendritic cells (DCs)-based antigen presentation. Depletion of DCs or CD8⁺ T cells eliminated the anti-tumor immune responses induced by UN treatment and weakened the synergistic anti-tumor efficacy with anti-PD-L1 antibody. Therefore, minimally invasive UN may provide a new therapeutic modality for ultrasound-assisted immunotherapy.

Origin of the broad-band noise in acoustic cavitation

The broad-band noise has been experimentally used to monitor the cavitation activity in a sonochemical reactor, an ultrasonic cleaning bath, a biological tissue, etc. However, the origin of the broad-band noise is still under debate. In the present review, two models for the mechanism of the broad-band noise are discussed. One is acoustic emissions from chaotically (non-periodically) pulsating bubbles. The other is acoustic emissions from bubbles with temporal fluctuation in the number of bubbles. It is suggested that the latter mechanism is sometimes dominant. Further studies are required on the role for bubble cluster dynamics as well as the bubble-bubble interaction in the broad-band noise especially at relatively low ultrasonic frequencies.

Temperature as a key parameter for graphene sono-exfoliation in water

Graphene dispersions in water are highly desirable for a range of applications such as biomedicines, separation membranes, coatings, inkjet printing and more. Recent novel research has been focussed on developing a green approach for scalable production of graphene. However, one important parameter, which is often neglected is the bulk temperature of the processing liquid. This paper follows our earlier work where optimal sono-exfoliation parameters of graphite in aqueous solutions were determined based on the measured acoustic pressure fields at various temperatures and input powers. Here, we take the next step forward and demonstrate using systematic characterisation techniques and acoustic pressure measurements that sonication-assisted liquid phase exfoliation (LPE) of graphite powder can indeed produce high quality few layer graphene flakes in pure water at a specific temperature, i.e. 40 °C, and at an optimised input generator power of 50%, within 2-h of processing. UV-vis analysis also revealed that the exfoliation, stability and uniformity of dispersions were improved with increasing temperature. We further confirmed the successful exfoliation of graphene sheets with minimal level of defects in the optimized sample with the help of Raman microscopy and transmission electron microscopy. This study demonstrated that understanding and controlling processing temperature is one of the key parameters for graphene exfoliation in water which offers a potential pathway for its large-scale production.

Use of Ultrasonic Cleaning Technology in the Whole Process of Fruit and Vegetable Processing

In an era of rapid technological development, ultrasound technology is being used in a wide range of industries. The use of ultrasound technology in fruit and vegetable processing to improve production efficiency and product quality has been an important research topic. The cleaning of whole fresh fruits and vegetables is an important part of fruit and vegetable processing. This paper discusses the development process of components of the ultrasonic equipment, the application of ultrasonic technology in fruit and vegetable cleaning, and the research advances in ultrasonic cleaning technology. Moreover, the feasibility of ultrasonication of fruits and vegetables for cleaning from the perspectives of microbial inactivation, commodity storage, and sensory analysis were discussed. Finally, the paper identified the inevitable disadvantages of cavitation noise, erosion, and tissue damage in fruit and vegetable processing and points out the future directions of ultrasonic fruit and vegetable cleaning technology.

Multiscale interactions of liquid, bubbles and solid phases in ultrasonic fields revealed by multiphysics modelling and ultrafast X-ray imaging

The volume of fluid (VOF) and continuous surface force (CSF) methods were used to develop a bubble dynamics model for the simulation of bubble oscillation and implosion dynamics under ultrasound. The model was calibrated and validated by the X-ray image data acquired by ultrafast synchrotron X-ray. Coupled bubble interactions with bulk graphite and freely moving particles were also simulated based on the validated model. Simulation and experiments quantified the surface instability developed along the bubble surface under the influence of ultrasound pressure fields. Once the surface instability exceeds a certain amplitude, bubble implosion occurs, creating shock waves and highly deformed, irregular gas-liquid boundaries and smaller bubble fragments. Bubble implosion can produce cyclic impulsive stresses sufficient enough to cause µs fatigue exfoliation of graphite layers. Bubble-particle interaction simulations reveal the underlying mechanisms for efficient particle dispersion or particle wrapping which are all strongly related to the oscillation dynamics of the bubbles and the particle surface properties.

Comparison of frequency domain and time domain methods for the numerical simulation of contactless ultrasonic cavitation

The use of a top-mounted electromagnetic induction coil has been demonstrated as a contactless alternative to traditional ultrasonic treatment (UST) techniques that use an immersed mechanical sonotrode for the treatment of metals in the liquid state. This method offers similar benefits to existing UST approaches, including degassing, grain refinement, and dispersion of nanoparticles, while also preventing contact contamination due to erosion of the sonotrode. Contactless treatment potentially extends UST to high temperature or reactive melts. Generally, the method relies on acoustic resonance to reach pressure levels suitable for inertial cavitation and as a result the active cavitation volume tends to lie deep in the melt rather than in the small volume surrounding the immersed sonotrode probe. Consequently, (i) with suitable tuning of the coil supply frequency for resonance, the treatment volume can be made arbitrarily large, (ii) the problem of shielding and pressure wave attenuation suffered by the immersed sonotrode is avoided. However, relying on acoustic resonance presents problems: (i) the emergence of bubbles alters the speed of sound, resonance is momentarily lost, and cavitation becomes intermittent, (ii) as sound waves travel through and reflect on all the materials surrounding the melt, the sound characteristics of the crucible and supporting structures need to be carefully considered. The physics of cavitation coupled with this intermittent behaviour poses a challenge to sonotrode modelling orthodoxy, a problem we are trying to address in this publication. Two alternative approaches will be discussed, one of which is in the time domain and one in the frequency domain, which couple the solution of a bubble dynamics solver with that of an acoustics solver, to give an accurate prediction of the acoustic pressure generated by the induction coil. The time domain solver uses a novel algorithm to improve simulation time, by detecting an imminent bubble collapse and prescribing its subsequent behaviour, rather than directly solving a region that would normally require extremely small time steps. This way, it is shown to predict intermittent cavitation. The frequency domain solver for the first time couples the nonlinear Helmholtz model used for studying cavitation, with a background source term for the contribution of Lorentz forces. It predicts comparable RMS pressures to the time domain solver, but not the intermittent behaviour due to the underlying harmonic assumption. As further validation, the frequency domain method is also used to compare the generated acoustic pressure with that of traditional UST using a mechanical sonotrode.

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.

In-situ observations and acoustic measurements upon fragmentation of free-floating intermetallics under ultrasonic cavitation in water

Grain refinement in alloys is a well-known effect of ultrasonic melt processing. Fragmentation of primary crystals by cavitation-induced action in liquid metals is considered as one of the main driving mechanisms for producing finer and equiaxed grain structures. However, in-situ observations of the fragmentation process are generally complex and difficult to follow in opaque liquid metals, especially for the free-floating crystals. In the present study, we develop a transparent test rig to observe in real time the fragmentation potential of free-floating primary Al3Zr particles under ultrasonic excitation in water (an established analogue medium to liquid aluminium for cavitation studies). An effective treatment domain was identified and fragmentation time determined using acoustic pressure field mapping. For the first time, real-time high-speed imaging captured the dynamic interaction of shock waves from the collapsing bubbles with floating intermetallic particles that led to their fragmentation. The breakage sequence as well as the cavitation erosion pattern were studied by means of post-treatment microscopic characterisation of the fragments. Fragment size distribution and crack patterns on the fractured surface were then analysed and quantified. Application of ultrasound is shown to rapidly (<10 s) reduce intermetallic size (from 5 mm down to 10 μm), thereby increasing the number of potential nucleation sites for the grain refinement of aluminium alloys during melt treatment.

Base oil recovery from waste lubricant oil by polar solvent extraction intensified by ultrasound

This paper proposes a greener approach to the intensification of base oil recovery for truck engines (32,500 km of use) using ethanol, propan-2-ol, 2-methylpropan-1-ol, and butan-1-ol as solvents for the extraction of base oil, combining mechanical stirring (220 rpm) and ultrasound (25 °C, 24 kHz, and 400 W). The results indicated that the recovery yields of the base oil, using the mechanical stirring and ultrasound (MS-US) system, for ethanol, propan-2-ol, 2-methylpropan-1-ol, and butan-1-ol were approximately 3.1, 25.6, 71.6, and 85.5%, respectively. By contrast, the recovery yields using only mechanical stirring were 8.8, 28.9, 58.9, and 76.1%, respectively. The system with pre-extraction could effectively remove Ca (85.3-93.0%), Mg (67.2-82.9%), Na (31.7-62.5%), and Zn (0.0-71.7%). Finally, the results showed a reduction of almost 100% for the concentrations of Al, Cr, Fe, and Mo in the pre-extraction system. The mechanical stirring (5 min) and ultrasound (5 min) system were able to intensify the extraction process using environmentally friendly solvents.

Mechanisms of ultrasonic de-agglomeration of oxides through in-situ high-speed observations and acoustic measurements

Ultrasonic de-agglomeration and dispersion of oxides is important for a range of applications. In particular, in liquid metal, this is one of the ways to produce metal-matrix composites reinforced with micron and nano sized particles. The associated mechanism through which the de-agglomeration occurs has, however, only been conceptualized theoretically and not yet been validated with experimental observations. In this paper, the influence of ultrasonic cavitation on SiO2 and MgO agglomerates (commonly found in lightweight alloys as reinforcements) with individual particle sizes ranging between 0.5 and 10 μm was observed for the first time in-situ using high-speed imaging. Owing to the opacity of liquid metals, a de-agglomeration imaging experiment was carried out in de-ionised water with sequences captured at frame rates up to 50 kfps. In-situ observations were further accompanied by synchronised acoustic measurements using an advanced calibrated cavitometer, to reveal the effect of pressure amplitude arising from oscillating microbubbles on oxide de-agglomeration. Results showed that ultrasound-induced microbubble clusters pulsating chaotically, were predominantly responsible for the breakage and dispersion of oxide agglomerates. Such oscillating cavitation clusters were seen to capture the floating agglomerates resulting in their immediate disintegration. De-agglomeration of oxides occurred from both the surface and within the bulk of the aggregate. Microbubble clusters oscillating with associated emission frequencies at the subharmonic, 1st harmonic and low order ultra-harmonics of the driving frequency were deemed responsible for the breakage of the agglomerates.

Nanogenerator for determination of acoustic power in ultrasonic reactors

This paper presents the novel use of a sonochemical reaction product as a sensing material in self-powered ultrasonic reactor devices for determination of ultrasound parameters. A piezoelectric nanogenerator was fabricated via sonochemical synthesis of SbSeI nanowires compressed into a bulk sample. The prepared device was used to develop two fast and simple evaluation methods for acoustic power in liquid. A calibration procedure was carried out for both methods using a VCX-750 ultrasonic processor. The ultrasound acoustic power was varied within a 150 W to 750 W range and the corresponding nanogenerator electrical responses were measured. The voltage signals of the first method fit the best with theoretical dependence. The second technique was based on the application of the Fast Fourier Transform (FFT) to the measured electric output. The results of these two approaches were convergent. Acoustic power values of 255(8) W and 222(7) W were determined for the Sonic-6 reactor using theoretical dependence fitting to experimental data and FFT analysis, respectively. Developed sensing technology possesses great potential for sonochemistry applications.

Scale up design study on process vessel dimensions for ultrasonic processing of water and liquid aluminium

Scaling up ultrasonic cavitation melt treatment (UST) requires effective flow management with minimised energy requirements. To this end, container dimensions leading to the resonance play a crucial role in amplifying pressure amplitude for cavitation. To quantify the importance of resonance length during the treatment of liquid aluminium, we used calibrated high-temperature cavitometers (in the range of 8-400 kHz), to measure and record the acoustic pressure profiles inside the cavitation-induced environment of liquid Al and deionized water (used as an analogue to Al) excited at 19.5 kHz. To achieve a comprehensive map of the acoustic pressure field, measurements were conducted at three different cavitometer positions relative to the vibrating sonotrode probe and for a number of resonant and non-resonant container lengths based on the speed of sound in the treated medium. The results showed that the resonance length affected the pressure magnitude in liquid Al in all cavitometer positions, while water showed no sensitivity to resonance length. An important practical application of UST in aluminium processing concerns grain refinement. For this reason, grain size analysis of UST-treated Al-Cu-Zr-Ti alloy was used as an indicator of the melt treatment efficiency. The result showed that the treatment in a resonance tank of L=λ_Al (the wavelength of sound in Al) gave the best structure refinement as compared to other tested lengths. The data given here contribute to the optimisation of the ultrasonic process in continuous casting, by providing an optimum value for the critical compartment (e.g. in a launder of direct-chill casting) dimension.

Effects of High-Intensity Ultrasound on the Microstructure and Mechanical Properties of 2195 Aluminum Ingots

The microstructural refinement of 2195 aluminum alloy ingots is particularly important for improving their industrial applications and mechanical properties. Combined with vacuum casting and inert gas protection, scalable high-strength ultrasonic melt processing (USMT) technology was used to manufacture 2195 aluminum alloy cylindrical ingots. Then, the influence of USMT on the main microstructural components (primary α-Al grains, secondary phase network, and precipitated particles) was studied. Our experiments show that the main microstructure of the ingot was improved after the introduction of ultrasound. Compared to the ingot formed without USMT, the size and morphology of the primary α-Al phase were optimized. The agglomeration of coarsening secondary phases can be alleviated, and the large layered secondary phase network becomes discontinuous throughout the ingot under USMT. At the same time, the mechanical properties of the solidified aluminum alloy ingots were also tested, and comparisons were made between samples formed with and without USMT. The results show that the stress concentration caused by the large area of coarse secondary phase in the ingot leads to the decrease of mechanical properties.

Multiphysics Modelling of Ultrasonic Melt Treatment in the Hot-Top and Launder during Direct-Chill Casting: Path to Indirect Microstructure Simulation

This study concerns the numerical simulation of two competing ultrasonic treatment (UST) strategies for microstructure refinement in the direct-chill (DC) casting of aluminium alloys. In the first, more conventional, case, the sonotrode vibrating at 17.3 kHz is immersed in the hop-top to treat the sump melt pool, in the second case, the sonotrode is inserted between baffles in the launder. It is known that microstructure refinement depends on the intensity of acoustic cavitation and the residence time of the treated fluid in the cavitation zone. The geometry, acoustic field intensity, induced flow velocities, and local temperature are factors which affect this treatment. The mathematical model developed in this work couples flow velocity, acoustics modified by cavitation, heat transfer, and solidification at the macroscale, with Lagrangian refiner particles, used to determine: (a) their residence time in the active zones, and (b) their eventual distribution in the sump as a function of the velocity field. This is the first attempt at using particle models as an efficient, though indirect, alternative to microstructure simulation, and the results indicate that UST in the launder, assisted with baffle separators, yields a more uniform distribution of refining particles, avoiding the strong acoustic streaming jet that, otherwise, accompanies hot-top treatment, and may lead to the strong segregation of refining particles. Experiments conducted in parallel to the numerical studies in this work appeared to support the results obtained in the simulation.

Characterization of acoustic streaming in water and aluminum melt during ultrasonic irradiation

It is well known that ultrasonic cavitation causes a steady flow termed acoustic streaming. In the present study, the velocity of acoustic streaming in water and molten aluminum is measured. The method is based on the measurement of oscillation frequency of Karman vortices around a cylinder immersed into liquid. For the case of acoustic streaming in molten metal, such measurements were performed for the first time. Four types of experiments were conducted in the present study: (1) Particle Image Velocimetry (PIV) measurement in a water bath to measure the acoustic streaming velocity visually, (2) frequency measurement of Karman vortices generated around a cylinder in water, and (3) in aluminum melt, and (4) cavitation intensity measurements in molten aluminum. Based on the measurement results (1) and (2), the Strouhal number for acoustic streaming was determined. Then, using the same Strouhal number and measuring oscillation frequency of Karman vortices in aluminum melt, the acoustic streaming velocity was measured. The velocity of acoustic streaming was found to be independent of amplitude of sonotrode tip oscillation both in water and aluminum melt. This can be explained by the effect of acoustic shielding and liquid density.

On the governing fragmentation mechanism of primary intermetallics by induced cavitation

One of the main applications of ultrasonic melt treatment is the grain refinement of aluminium alloys. Among several suggested mechanisms, the fragmentation of primary intermetallics by acoustic cavitation is regarded as very efficient. However, the physical process causing this fragmentation has received little attention and is not yet well understood. In this study, we evaluate the mechanical properties of primary Al3Zr intermetallics by nano-indentation experiments and correlate those with in-situ high-speed imaging (of up to 1 Mfps) of their fragmentation process by laser-induced cavitation (single bubble) and by acoustic cavitation (cloud of bubbles) in water. Intermetallic crystals were chemically extracted from an Al-3 wt% Zr alloy matrix. Mechanical properties such as hardness, elastic modulus and fracture toughness of the extracted intermetallics were determined using a geometrically fixed Berkovich nano-diamond and cube corner indenter, under ambient temperature conditions. The studied crystals were then exposed to the two cavitation conditions mentioned. Results demonstrated for the first time that the governing fragmentation mechanism of the studied intermetallics was due to the emitted shock waves from the collapsing bubbles. The fragmentation caused by a single bubble collapse was found to be almost instantaneous. On the other hand, sono-fragmentation studies revealed that the intermetallic crystal initially underwent low cycle fatigue loading, followed by catastrophic brittle failure due to propagating shock waves. The observed fragmentation mechanism was supported by fracture mechanics and pressure measurements using a calibrated fibre optic hydrophone. Results showed that the acoustic pressures produced from shock wave emissions in the case of a single bubble collapse, and responsible for instantaneous fragmentation of the intermetallics, were in the range of 20-40 MPa. Whereas, the shock pressure generated from the acoustic cavitation cloud collapses surged up to 1.6 MPa inducing fatigue stresses within the crystal leading to eventual fragmentation.

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.

Simulation of Ultrasonic Induced Cavitation and Acoustic Streaming in Liquid and Solidifying Aluminum

Ultrasonic treatment (UST), more precisely, cavitation and acoustic streaming, of liquid light metal alloys is a very promising technology for achieving grain and structure refinement, and therefore, better mechanical properties. The possibility of predicting these process phenomena is an important requirement for understanding, implementing, and scaling this technology in the foundry industry. Using an established (casting) computational fluid dynamics (CFD)-simulation tool, we studied the ability of this software to calculate the onset and expansion of cavitation and acoustic streaming for the aluminum alloy A356, partly depending on different radiator geometries. A key aspect was a holistic approach toward pressure distribution, cavitation, and acoustic streaming prediction, and the possibility of two- and (more importantly) three-dimensional result outputs. Our feasibility analysis showed that the simulation tool is able to predict the mentioned effects and that the results obtained are in good agreement with the results and descriptions of previous investigations. Finally, capabilities and limitations as well as future challenges for further developments are discussed.

Bubble dynamics and cavitation intensity in milli-scale channels under an ultrasonic horn

Under a vibrating ultrasonic horn device, intense cavitation occurs but is restricted to a small volume due to strong attenuation effects. In this study, milli-scale channels were introduced under the horn. The effect of this on the cavitation development and intensity within the channels were explored. High speed videography of up to 100,000 fps and acoustic signal acquisition through hydrophone were conducted. Cavitation intensity was observed to increase within the channels as compared to free field condition. Bubble density increased with a decrease in channel diameter and a rise in ultrasonic amplitude. Furthermore, an intriguing phenomenon of large bubble cluster formation near the channel exit (20 mm away from the horn surface) was detected. The oscillation behaviour of these clusters is dependent on both channel diameter and ultrasonic amplitude. At the maximum ultrasonic amplitude, the clusters reached maximum radiuses exceeding 3 mm and collapsed violently. Repetitive transient collapses near the exit region suggest that the introduction of milli-scale channels could extend the effective cavitation zone length and enhance the overall cavitation intensity under an ultrasonic horn.

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.

Effects of Ultrasonic Introduced by L-Shaped Ceramic Sonotrodes on Microstructure and Macro-Segregation of 15t AA2219 Aluminum Alloy Ingot

The effects of ultrasonic introduced by L-shaped sonotrodes made of high-temperature-resistant ceramic on the microstructure and macro-segregation of solidifying 15t AA2219 aluminum alloy ingots have been examined in the present study. The macroscopic morphology of the corrosion of the sonotrode has been observed. Grain refinement has been observed, the shape and size of the precipitated phase of the ingot were counted, and the degree of segregation along the transverse direction at 500 mm from the head of the ingot has been evaluated. The results reveal that the L-shaped ceramic ultrasonic introduction device can effectively avoid the erosion of high-temperature melt on the sonotrode and the heat radiation of the high-temperature heat flow to the transducer. Furthermore, the scanning electron microscope (SEM) and chemical composition detection results also indicate that the inter-dendritic micro-segregation of the equiaxed grains can be reduced, and the macro-segregation of the chemical composition of the ingot can be suppressed, and more homogeneous microstructures can be obtained when ultrasonic has been applied during solidification.

A computational and experimental study on acoustic pressure for ultrasonically formed oil-in-water emulsion

In the field of ultrasonic emulsification, the formation and cavitation collapse is one major factor contributing to the formation of micro- and nano-sized emulsion droplets. In this work, a series of experiments were conducted to examine the effects of varying the ultrasonic horn's position to the sizes of emulsion droplets formed, in an attempt to compare the influence of the simulated acoustic pressure fields to the experimental results. Results showed that the intensity of the acoustic pressure played a vital role in the formation of smaller emulsion droplets. Larger areas with acoustic pressure above the cavitation threshold in the water phase have resulted in the formation of smaller emulsion droplets ca. 250 nm and with polydispersity index of 0.2-0.3. Placing the ultrasonic horn at the oil-water interface has hindered the formation of small emulsion droplets, due to the transfer of energy to overcome the interfacial surface tension of oil and water, resulting in a slight reduction in the maximum acoustic pressure, as well as the total area with acoustic pressures above the cavitation threshold. This work has demonstrated the influence of the position of the ultrasonic horn in the oil and water system on the final emulsion droplets formed and can conclude the importance of generating acoustic pressure above the cavitation threshold to achieve small and stable oil-in-water emulsion.

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.

Numerical modelling of acoustic streaming during the ultrasonic melt treatment of direct-chill (DC) casting

Acoustic streaming and its attendant effects in the sump of a direct-chill (DC) casting process are successfully predicted under ultrasonic treatment for the first time. The proposed numerical model couples acoustic cavitation, fluid flow, heat and species transfer, and solidification to predict the flow pattern, acoustic pressure, and temperature fields in the sump. The model is numerically stable with time steps of the order of 0.01 s and therefore computationally attractive for optimization studies necessitating simulation times of the order of a minute. The sump profile is altered by acoustic streaming, with the slurry region depressed along the centreline of the billet by a strong central jet. The temperature gradient in the transition zone is increased, potentially interfering with grain refinement. The cooling rate in the sump is also altered, thereby modifying the dendrite arm spacing of the as-cast billet. The relative position of the sonotrode affects the sump profile, with the sump depth decreased by around 5 mm when the sonotrode is moved above the graphite ring level by 100 mm. The acoustic streaming jet penetrates into the slurry zone and, as a result, the growth direction of dendritic grains in the off-centre position is altered.

Experimental and numerical investigation of cavitation-induced erosion in thermal sprayed single splats

Hydraulic components are coated by thermal spraying to protect them against cavitation erosion. These coatings are built up by successive deposition of single splats. The behavior of a single splat under mechanical loading is still very vaguely understood. Yttria-stabilized zirconia (YSZ) and stainless-steel splats were obtained by plasma spraying onto stainless steel substrates. The velocity and temperature of particles upon impact were measured and the samples were subsequently exposed to cavitation erosion tests. An acoustic cavitation simulation estimated the water jet velocity and hammer stresses exerted by bubble collapse on the surface of the specimen. Although the results suggested that high stress levels resulted from cavitation loading, it was clear that weak adhesion interfaces played a crucial role in the accelerated cavitation-induced degradation.