Ultrasound cavitation induced nucleation in metal solidification: An analytical model and validation by real-time experiments

Ultrasonic field-assisted metal additive manufacturing (U-FAAM): Mechanisms, research and future directions

Metal additive manufacturing (AM) is a disruptive technology that provides unprecedented design freedom and manufacturing flexibility for the forming of complex components. Despite its unparalleled advantages over traditional manufacturing methods, the existence of fatal issues still seriously hinders its large-scale industrial application. Against this backdrop, U-FAAM is emerging as a focus, integrating ultrasonic energy into conventional metal AM processes to harness distinctive advantages. This work offers an up-to-date, specialized review of U-FAAM, articulating the integrated modes, mechanisms, pivotal research achievements, and future development trends in a systematic manner. By synthesizing existing research, it highlights future directions in further optimizing process parameters, expanding material applicability, etc., to advance the industrial application and development of U-FAAM technology.

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.

Preparation of boron nitride nanosheets by glucose-assisted ultrasonic cavitation exfoliation

Boron nitride nanosheets (BNNSs) have been widely used in many fields due to their excellent properties. However, low preparation rates and difficulty in functionalization hinder their further development. This study proposes a novel glucose-assisted ultrasonic cavitation exfoliation (GAUCE) method with glucose as an auxiliary solution to prepare BNNSs. Results show that the method has a high preparation yield of 55.58%, which is higher than the average preparation yield of 33.86%. The mechanism of preparing BNNSs by GAUCE was also investigated. The exfoliation of BNNSs was achieved using the energy of ultrasonic cavitation bubble collapse, which will break the interlayer forces in h-BN. The grafting of hydroxyl groups decomposed by glucose on the edge and surface of BNNSs during cavitation prevented the re-aggregation of the nanosheets, thereby increasing the exfoliation yield of BNNSs. In addition, the contact angle of BNNSs prepared by GAUCE was reduced, and the hydrophilicity was greatly improved.

Effect of Ultrasonic Vibration on Microstructure and Fluidity of Aluminum Alloy

The effect of ultrasonic vibration on the fluidity and microstructure of cast aluminum alloys (AlSi9 and AlSi18 alloys) with different solidification characteristics was investigated. The results show that ultrasonic vibration can affect the fluidity of alloys in both solidification and hydrodynamics aspects. For AlSi18 alloy without dendrite growing solidification characteristics, the microstructure is almost not influenced by ultrasonic vibration, and the influence of ultrasonic vibration on its fluidity is mainly in hydrodynamics aspects. That is, appropriate ultrasonic vibration can improve fluidity by reducing the flow resistance of the melt, but when the vibration intensity is high enough to induce turbulence in the melt, the turbulence will increase the flow resistance greatly and decrease fluidity. However, for AlSi9 alloy, which obviously has dendrite growing solidification characteristics, ultrasonic vibration can influence solidification by breaking the growing α (Al) dendrite, consequently refining the solidification microstructure. Ultrasonic vibration could then improve the fluidity of AlSi9 alloy not only from the hydrodynamics aspect but also by breaking the dendrite network in the mushy zone to decrease flow resistance.

Microstructure evolution and grain refinement of ultrasonic-assisted soldering joint by using Ni foam reinforced Sn composite solder

In this investigation, ultrasonic-assisted soldering at 260 °C in air produced high strength and high melting point Cu connections in 60 s using Ni foam reinforced Sn composite solder. Systematically examined were the microstructure, grain morphology, and shear strength of connections made with various porosities of Ni foam composite solders. Results shown that Ni foams as strengthening phases could reinforce Sn solder effectively. The addition of Ni foam accelerated the metallurgical reaction due to great amount of liquid/solid interfaces, and refined the intermetallic compounds (IMCs) grains by ultrasonic cavitation. The joints had different IMCs by using Ni foam with different porosity. Layered (Cu,Ni)₆Sn₅ and (Ni,Cu)₃Sn₄ phases both existed in Cu/Ni60-Sn/Cu joint while only (Cu,Ni)₆Sn₅ IMCs grew in Cu/Ni98-Sn/Cu joint. As ultrasonic time increasing, Ni skeletons were dissolved and the IMCs were peeled off from substrates and broken into small particles. And then, the IMCs gradually dissociated into refined particles and distributed homogeneously in the whole soldering seam under cavitation effects. Herein, the Cu/Ni60-Sn/Cu joint ultrasonically soldered for 60 s exhibited the highest shear strength of 86.9 MPa, as well as a high melting point about 800 ℃ for the solder seam composed of Ni skeletons and Ni-Cu-Sn IMCs. The characterization indicated that the shearing failure mainly occurred in the interlayer of the soldering seam. The homogeneous distributed granular IMCs and Ni skeletons hindered the crack propagation and improved the strength of Cu alloy joints.

Interactions between a cavitation bubble and solidification front under the effects of ultrasound: Experiments and lattice Boltzmann modeling

The phenomena of melting and dendritic fragmentation are captured by using an in-situ device during the ultrasound-assisted solidification of a succinonitrile-acetone (SCN-ACE) alloy. The experimental results show that the dendrite arms detach from primary trunk due to the melting of the solid phase, which is caused by a moving ultrasound cavitation bubble. To quantify the interactions between the ultrasound cavitation bubble and the solidification front, a coupled lattice Boltzmann (LB) model is developed for describing the fields of temperature, flow, and solid fraction, and their interactions. The multi-relaxation-time (MRT) scheme is applied in the LB model to calculate the liquid-gas flow field, while the Bhatnagar-Gross-Krook (BGK) equation is executed to simulate the evolution of temperature. The kinetics of solidification and melting are calculated according to the lever rule based on the SCN-ACE phase diagram. After the validation of the LB model by an analytical model, the morphologies of the cavitation bubble and solidification front are simulated. It is revealed that the solidification interface melts due to the increase of the temperature nearby the cavitation bubble in ultrasonic field. The simulated morphologies of the cavitation bubble and solidification front are compared well with the experimental micrograph. Quantitative investigations are carried out for analyzing the melting rate of the solidification front under different conditions. The simulated data obtained from LB modeling and theoretical predictions reasonably accord with the experimental results, demonstrating that the larger the ultrasonic intensity, the faster the melting rate. The present study not only reveals the evolution of the solidification front shape caused by the cavitation bubbles, which is invisible in the ultrasound-assisted solidification process of practical alloys, but also reproduces the complex interactions among the temperature field, acoustic streaming, and multi-phase flows.

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.

An overview and critical assessment of the mechanisms of microstructural refinement during ultrasonic solidification of metals

A refined, equiaxed grain structure and the formation of finer primary intermetallic phases are some of the notable benefits of ultrasonic processing of liquid/solidifying melts. Ultrasonic treatment (UST) has been widely explored in Al and Mg-based alloys due to its operational versatility and scalability. During UST, the refinement of grain and primary intermetallic phases occurs via cavitation-induced fragmentation mechanisms. In addition, UST improves the efficiency (activation of particles) of the conventional grain refinement process when potent particles are added through master alloys. Though the UST's ability to produce refined as-cast structures is well recognized, the understanding of the refinement mechanisms is still debated and unresolved. Significant efforts have been devoted to understanding these mechanisms through the use of sophisticated techniques such as in-situ/ real-time observation, lab-scale and commercial-scale casting processes. All these studies aim to demonstrate the significance of cavitation, fragmentation modes, and alloy chemistry in microstructure refinement. Although the physical effects of cavitation and acoustic streaming (fluid flow) are primary factors influencing the refinement, the dominant grain refinement mechanisms are affected by several solidification variables and casting conditions. Some of these include melt volume, solute, cooling rate, potent particles, grain growth (equiaxed, columnar or dendritic), and the cold zones of the casting where the onset of nucleation occurs. This review aims to provide a better insight into solidification variables emphasizing the importance of cold zones in generating fine structures for small- and large-volume (direct chill) castings. Another important highlight of this review is to present the relatively less explored mechanism of (acoustic) vibration-induced crystallization and discuss the role of cavitation in achieving a refined ingot structure.

Effect of ultrasonic melt processing and Al-Ti-B on the microstructural refinement of recycled Al alloys

Refining the α-Al grain size and controlling the morphology of intermetallic phases during solidification of Al alloys using ultrasonic melt processing (USMP) and Al-Ti-B have been extensively used in academic and industry. While, their synergy effect on the formation of these phases has not yet clearly demonstrated. In this paper, the influence of USMP and Al-Ti-B on the solidified microstructure of multicomponent Al-4.5Cu-0.5Mn-0.5Mg-0.2Si-xFe alloys (x = 0.7, and 1.2 wt%) has been comparatively studied. The results show that the USMP + Al-Ti-B method produce a more profound refinement effect than the individual methods. In addition, the area of single Fe-rich phases in both alloys with USMP + Al-Ti-B are also refined compared with conventional methods. A mechanism is proposed for the refinement, which are the deagglomerated TiB₂ parties induced by USMP providing more effective nucleation sites for α-Al, and the refined interdendritic regions limited the growth of Fe-rich phases in the following eutectic reaction. Finally, the application of combined USMP + Al-Ti-B methods is feasible in microstructural refinement, resulting in the improving the casting soundness and mechanical properties of alloys.

Antibacterial mechanism of linalool emulsion against Pseudomonas aeruginosa and its application to cold fresh beef

Pseudomonas aeruginosa (P. aeruginosa) is the dominant spoilage bacterium in cold fresh beef. The current strategy is undertaken to overcome the low water solubility of linalool by encapsulating linalool into emulsions. The results of field emission scanning electron microscopy and particle size distribution revealed that the appearance of the bacterial cells was severely disrupted after exposure to linalool emulsion (LE) with an minimum inhibitory concentration (MIC) of 1.5 mL/L. Probes combined with fluorescence spectroscopy were performed to detect cell membrane permeability, while intracellular components (protein and ion leakage) and crystal violet staining were further measured to characterize cell membrane integrity and biofilm formation ability. The results confirmed that LE could destroy the structure of the cell membrane, thereby leading to the leakage of intracellular material and effective removal of biofilms. Molecular docking confirmed that LE can interact with the flagellar cap protein (FliD) and DNA of P. aeruginosa, inhibiting biofilm formation and causing genetic damage. Furthermore, the results of respiratory metabolism and reactive oxygen species (ROS) accumulation revealed that LE could significantly inhibit the metabolic activity of P. aeruginosa and induce oxidative stress. In particular, the inhibition rate of LE on P. aeruginosa was 23.03% and inhibited mainly the tricarboxylic acid cycle (TCA). Finally, LE was applied to preserve cold fresh beef, and the results showed that LE could effectively inhibit the activity of P. aeruginosa and delay the quality change of cold fresh beef during the storage period. These results are of great significance to developing natural preservatives and extending the shelf life of cold fresh beef.