Investigation on ultrasonic cavitation erosion of TiMo and TiNb alloys in sulfuric acid solution

Two kinds of Ti-alloys, i.e., TiMo and TiNb alloys are manufactured in this paper, and their ultrasonic cavitation erosion behaviors in 0.1 M H₂SO₄ solution are evaluated by the mean depth erosion (MDE), SEM and white light photograph. The results show that MDE of TiMo and TiNb alloys obviously increase with increasing the cavitation erosion time, however, they evidently decrease with the increment of Mo or Nb content at each fixed cavitation erosion time, and even some large blank areas (uneroded areas) still exist on the sample surface after ultrasonic cavitation erosion for 2 h in the case of Ti10Mo and Ti20Nb samples, implying the enhanced anti-cavitation erosion property of Ti-alloy by adding Mo or Nb element. The MDE of Ti10Mo or Ti20Nb sample is lower than that of TC4 sample in the case of each cavitation erosion time, indicating the better cavitation erosion resistance of of Ti10Mo or Ti20Nb sample. The influences of Mo and Nb on the passivity of TiMo and TiNb alloys during the ultrasonic cavitation erosion are detected by potentiodynamic curves. The results display that Ti, TC4, TixMo (x = 1, 5, 10) and TixNb (x = 5, 10, 20) samples are all almost in the passive state within the potential region from 0V_SCE to 1.5V_SCE during ultrasonic cavitation erosion, and the passive current density evidently decreases with increasing Mo or Nb content, indicating the enhanced passive characteristic by adding Mo or Nb alloys during the ultrasonic cavitation erosion.     

Evolution of surface roughness of some metallic materials in cavitation erosion

The evolution of surface roughness of three common metallic materials (316L stainless steel, CP titanium, and brass) in ultrasonic vibratory cavitation tests was monitored using profilometric measurements. Three stages of roughness change, based on the rate of change of the mean surface roughness d(Ra)/dt, may be identified. In stage I (initial stage), Ra increases almost linearly with the test time; in stage II (transition stage), the rate decreases until stage III (steady-state stage) is reached, in which Ra remains unchanged. Concurrent measurements of mass loss in the ultrasonic cavitation test indicated that stage I approximately coincides with the incubation stage, stage II approximately coincides with the acceleration stage, and stage III approximately coincides with the maximum erosion rate stage as defined by ASTM Standard G 32. Compared with conventional mass loss measurements in assessing material degradation in cavitation erosion, surface roughness measurements provide an alternative and convenient method which possesses several advantages. In the first place, change in surface roughness provides information of material response before mass loss is detected. Secondly, there is no restriction of the size of the component, while weighing is suitable for small samples only. Thirdly, mass loss reflects erosion of the whole surface under cavitation attack, and the mean depth of penetration or erosion only gives an average loss, while in roughness measurement, damage in specific locations may be studied. The present study indicates that roughness measurement may constitute a practical method for monitoring damage in industrial ultrasonic cleaners.     

Effect of micro-particles on cavitation erosion of Ti6Al4V alloy in sulfuric acid solution

The influences of micro-particles on ultrasonic cavitation erosion of Ti6Al4V alloy in 0.1 M H₂SO₄ solution were investigated using mass loss weight, scanning electron microscopy (SEM) and white light interferometer. Mass loss results revealed that the cavitation erosion damage obviously decreased with increasing particle size and mass concentration. Open circuit potential recorded during cavitation erosion shifted to positive direction with the decreased mass loss. Meanwhile, the mass loss sharply decreased with applying a positive potential during the entire ultrasonic cavitation erosion, and the relationship between the open circuit potential and the cavitation erosion resistance was discussed.     

Ultrasonic cavitation erosion of 316L steel weld joint in liquid Pb-Bi eutectic alloy at 550 °C

Liquid lead-bismuth eutectic alloy (LBE) is applied in the Accelerator Driven transmutation System (ADS) as the high-power spallation neutron targets and coolant. A 19.2 kHz ultrasonic device was deployed in liquid LBE at 550 °C to induce short and long period cavitation erosion damage on the surface of weld joint, SEM and Atomic force microscopy (AFM) were used to map out the surface properties, and Energy Dispersive Spectrometer (EDS) was applied to the qualitative and quantitative analysis of elements in the micro region of the surface. The erosion mechanism for how the cavitation erosion evolved by studying the element changes, their morphology evolution, the surface hardness and the roughness evolution, was proposed. The results showed that the pits, caters and cracks appeared gradually on the erode surface after a period of cavitation. The surface roughness increased along with exposure time. Work hardening by the bubbles impact in the incubation stage strengthened the cavitation resistance efficiently. The dissolution and oxidation corrosion and cavitation erosion that simultaneously happened in liquid LBE accelerated corrosion-erosion process, and these two processes combined to cause more serious damage on the material surface. Contrast to the performance of weld metal, base metal exhibited a much better cavitation resistance.     

Effects of Ce,Sm and Yb on cavitation erosion of NAB alloy in 3.5% NaCl solution

The influences of Ce, Sm and Yb on cavitation erosion of NAB alloy in 3.5% NaCl solution are evaluated using mass loss, SEM, 3D morphology and Tafel plot, respectively. The results show that the addition of Ce or Sm or Yb enhances the mechanical property of NAB alloy, and the sizes of κ_Ⅰ and κ_Ⅱ phases within NAB alloy decrease with adding Ce or Sm or Yb, resulting in the prevention of the propagation of the cracks caused by cavitation erosion initially originated at the phase boundaries between α and κ phases, and finally the cavitation erosion damage significantly decreases with adding Ce or Sm or Yb. The corrosion of NAB alloy in 3.5% NaCl solution can promote the cavitation erosion of NAB alloy, while the corrosion resistance of NAB alloy increases with the addition of Ce or Sm or Yb, and then the cavitation erosion resistance is accordingly improved with the addition of rare earth element.     

Classification of regimes determining ultrasonic cavitation erosion in solid particle suspensions

Although the factors that influence ultrasonic cavitation erosion in solid particle suspensions have been extensively studied, the role that solid particles play in the cavitation process remains poorly understood. The ultrasonic cavitation erosion of AISI 1045 carbon steel was studied in the presence of monodisperse silica particles (10–100 μm, 0.5–20 vol%) suspended in transformer oil. Based on our results, we propose an overview of the possible influencing mechanisms of particle addition for specific particle sizes and concentrations. Four major regimes, namely a viscosity-enhancing regime (V), a particle-impinging regime (I), a particle-shielding regime (S), and a nuclei-adding regime (A) are identified, and their dependence on suspended particle characteristics is analyzed. The VISA regimes, in essence, reflect the viscous and inertial effects of suspended particles, and the way in which particle–particle interactions and heterogeneous nucleation affect erosion. This regime-based framework provides a better understanding of the dominant factors controlling the erosive wear caused by cavitation in the presence of solid particles, and provides a guide for erosion prediction and prevention.     

Sonochemiluminescence observation and acoustic detection of cavitation induced by pulsed HIFU at a tissue–fluid interface

The aim of this study is to investigate the mechanism of the erosion process induced by 1.2 MHz pulsed high-intensity focused ultrasound (pulsed HIFU). By using Sonochemiluminescence (SCL) photograph, the initiation and maintenance of active cavitation were observed. In order to understand the role of both inertial cavitation and stable cavitation, a passive cavitation detection (PCD) transducer was used. Since the exposure variables of HIFU are important in the controlled ultrasound tissue erosion, the influence of pulse length (PL) and duty cycle (DC, T_on:T_off) has been examined. The results of tissue hole, SCL observation and acoustic detection revealed that the erosion was highly efficient for shorter PL. For higher DCs, the area of SCL increased with increasing PL. For lower DCs, the area of SCL increased with increasing PL from 10 to 20 μs and then kept constant. For all PLs, the intensity of SCL decreased with lower DC. For all DCs, the intensity of SCL per unit area (the ratio of SCL intensity to SCL area) also decreased with increasing PL from 10 to 80 μs, which suggested that the higher the intensity of SCL is, the higher the efficiency of tissue erosion is. At DC of 1:10, the position of the maximum pixel in SCL pictures was distant from the tissue–fluid interface with the increasing PL because of shielding effect. By the comparison of inertial cavitation dose (ICD) and the stable cavitation dose (SCD), the mechanisms associated with inertial cavitation are very likely to be the key factor of the erosion process.     

Cavitation erosion mechanism of titanium alloy radiation rods in aluminum melt

Ultrasound radiation rods play a key role in introducing ultrasonic to the grain refinement of large-size cast aluminum ingots (with diameter over 800 mm), but the severe cavitation corrosion of radiation rods limit the wide application of ultrasonic in the metallurgy field. In this paper, the cavitation erosion of Ti alloy radiation rod (TARR) in the semi-continuous direct-chill casting of 7050 Al alloy was investigated using a 20 kHz ultrasonic vibrator. The macro/micro characterization of Ti alloy was performed using an optical digital microscopy and a scanning electron microscopy, respectively. The results indicated that the cavitation erosion and the chemical reaction play different roles throughout different corrosion periods. Meanwhile, the relationship between mass-loss and time during cavitation erosion was measured and analyzed. According to the rate of mass-loss to time, the whole cavitation erosion process was divided into four individual periods and the mechanism in each period was studied accordingly.     

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.     

Experiment investigation on effects of elastic modulus on cavitation erosion of silicone rubber

Research into cavitation phenomena in various fields shows that the elastic modulus of a boundary has a potential impact on cavitation erosion. To obtain the direct relationship between the elastic modulus of the boundary and cavitiation erosion, single-layer samples with different chemical composition and moduli, and double-layer samples with different elastic moduli and the same surface layer material, were prepared with silicone rubber. The results of cavitation experiments on single-layer samples, show that the coating chemical composition and mechanical properties together affect the cavitation morphology of the coating, and dominant factors vary with erosion stage. Through the cavitation test of double-layer samples, it was found that there is a positive correlation between the elastic modulus of the coating and the degree of cavitation. This study helps us to understand the relationship between coating elastic modulus and cavitation more directly, and provides theoretical and technical guidance for the application of anti-cavitation for elastic coating in engineering.     

Ultrasonic cavitation erosion of gas nitrided Ti–6Al–4V alloys

Ultrasonic cavitation erosion experiments were performed on Ti–6Al–4V alloys samples in annealed, nitrided and nitrided and subsequently heat treated state. The protective oxide layer formed as a result of annealing and heat treatment after nitriding is eliminated after less than 30 min cavitation time, while the nitride layer lasts up to 90 min cavitation time. Once the protective layer is removed, the cavitation process develops by grain boundary erosion, leading to the expulsion of grains from the surface. The gas nitrided Ti–6Al–4V alloy, forming a Ti_xN surface layer, proved to be a better solution to improve the cavitation erosion resistance, compared to the annealed and nitrided and heat treated state, respectively. The analysis of the mean depth of erosion rate at 165 min cavitation time showed an improvement of the cavitation erosion resistance of the nitrided samples of up to 77% higher compared to the one of the annealed samples.     

The effect of chloride ions on the corroded surface layer of 00Cr22Ni5Mo3N duplex stainless steel under cavitation

The effects of Cl⁻ on the corroded surface layer of 00Cr22Ni5Mo3N duplex stainless steel under cavitation in chloride solutions were investigated using nanoindentation in conjunction with XRD and XPS. The results demonstrate that Cl⁻ had a strong effect on the nano-mechanical properties of the corroded surface layer under cavitation, and there was a threshold Cl⁻ concentration. Furthermore, a close relationship between the nano-mechanical properties and the cavitation corrosion resistance of 00Cr22Ni5Mo3N duplex stainless steel was observed. The degradation of the nano-mechanical properties of the corroded surface layer was accelerated by the synergistic effect between cavitation erosion and corrosion. A key factor was the adsorption of Cl⁻, which caused a preferential dissolution of the ferrous oxides in the passive film layer on the corroded surface layer. Cavitation further promoted the preferential dissolution of the ferrous oxides in the passive film layer. Simultaneously, cavitation accelerated the erosion of the ferrite in the corroded surface layer, resulting in the degradation of the nano-mechanical properties of the corroded surface layer on 00Cr22Ni5Mo3N duplex stainless steel under cavitation.     

Ultrasonic cavitation erosion of high-velocity oxygen-fuel (HVOF) sprayed near-nanostructured WC–10Co–4Cr coating in NaCl solution

The high-velocity oxygen-fuel (HVOF) spraying process was used to prepare near-nanostructured WC–10Co–4Cr coating. The cavitation erosion behavior and mechanism of the coating in 3.5 wt.% NaCl solution were analyzed in detail. The results showed that the amorphous phase and WC grain were present in the coating. The cavitation erosion resistance of the coating was about 1.27 times that of the stainless steel 1Cr18Ni9Ti under the same testing conditions. The effects of erosion time on the microstructural evolution were discussed. It was revealed that cracks initiated at the edge of pre-existing pores and propagated along the carbide–binder interface, leading to the pull-out of carbide particle and the formation of pits and craters on the surface. The main failure mechanism of the coating was erosion of the binder phases, brittle detachment of hard phases and formation of pitting corrosion products.     

In-situ SEM observations of ultrasonic cavitation erosion behavior of HVOF-sprayed coatings

Several typical high-velocity oxy-fuel (HVOF)-sprayed coatings, including WC-10Co4Cr coatings, Co-based coatings, WC-10Co4Cr/Co-based composite coatings, and Fe-based amorphous/nanocrystalline coatings were fabricated, and their cavitation behavior was evaluated in deionized water. Further, in-situ SEM surface observations were used to understand the microstructure of tested coatings. The results show that cavitation erosion initially occurred at pre-existing defects in the coatings. Meanwhile, it was found that cavitation erosion damage of the WC-10Co4Cr/Co-based composite coating, which contained a hard reinforcing phase (WC-10Co4Cr phase) and a soft matrix phase (Co-based phase), preferentially occurred at or around pores and microcracks in the reinforcement, rather than in the defect free matrix. This suggested that defects were a critical contributing factor to cavitation damage of the composite coatings. Furthermore, a mechanism was suggested to explicate the cavitation behavior of composite coatings. The approach of using in-situ SEM surface observations proved to be useful for the analysis of the cavitation mechanism of engineering materials and protective coatings.     

高速水流中旋涡空化所引起的空蚀和振动

为了研究旋涡空化所引起的空蚀和振动观象以及二者的关系,采用高速摄影的方法,观察了发生在射流放水阀山部的空化形态。采用快速富里叶变换（FFT）分析了空化所引起的振动。采用失重法,进行了空蚀实验。结果表明,旋涡空化能引起严重的空蚀和剧烈的振动。在旋涡空化发展的个同阶段,其所导致的振动和空蚀呈观了个同的特性。当Sσ>0.74时,随空化数的变化,振动和空蚀呈现了相同的变化趋势,但是,在0.50<σ<0.74的范围内,振动和空蚀呈现了相反的变化趋势。这是由于水流中空化旋涡的数目和形态随空化数的变化,以及旋涡空化引起振动和空蚀的机理不同所造成的。     

Nakagami-m parametric imaging for characterization of thermal coagulation and cavitation erosion induced by HIFU

Nowadays, both thermal and mechanical ablation techniques of HIFU associated with cavitation have been developed for noninvasive treatment. A specific challenge for the successful clinical implementation of HIFU is to achieve real-time imaging for the evaluation and determination of therapy outcomes such as necrosis or homogenization. Ultrasound Nakagami-m parametric imaging highlights the degrading shadowing effects of bubbles and can be used for tissue characterization. The aim of this study is to investigate the performance of Nakagami-m parametric imaging for evaluating and differentiating thermal coagulation and cavitation erosion induced by HIFU. Lesions were induced in basic bovine serum albumin (BSA) phantoms and ex vivo porcine livers using a 1.6 MHz single-element transducer. Thermal and mechanical lesions induced by two types of HIFU sequences respectively were evaluated using Nakagami-m parametric imaging and ultrasound B-mode imaging. The lesion sizes estimated using Nakagami-m parametric imaging technique were all closer to the actual sizes than those of B-mode imaging. The p-value obtained from the t-test between the mean m values of thermal coagulation and cavitation erosion was smaller than 0.05, demonstrating that the m values of thermal lesions were significantly different from that of mechanical lesions, which was confirmed by ex vivo experiments and histologic examination showed that different changes result from HIFU exposure, one of tissue dehydration resulting from the thermal effect, and the other of tissue homogenate resulting from mechanical effect. This study demonstrated that Nakagami-m parametric imaging is a potential real-time imaging technique for evaluating and differentiating thermal coagulation and cavitation erosion.     

Cavitation erosion by shockwave self-focusing of a single bubble

The ability of cavitation bubbles to effectively focus energy is made responsible for cavitation erosion, traumatic brain injury, and even for catalyse chemical reactions. Yet, the mechanism through which material is eroded remains vague, and the extremely fast and localized dynamics that lead to material damage has not been resolved. Here, we reveal the decisive mechanism that leads to energy focusing during the non-spherical collapse of cavitation bubbles and eventually results to the erosion of hardened metals. We show that a single cavitation bubble at ambient pressure close to a metal surface causes erosion only if a non-axisymmetric energy self-focusing is at play. The bubble during its collapse emits shockwaves that under certain conditions converge to a single point where the remaining gas phase is driven to a shockwave-intensified collapse. We resolve the conditions under which this self-focusing enhances the collapse and damages the solid. High-speed imaging of bubble and shock wave dynamics at sub-picosecond exposure times is correlated to the shockwaves recorded with large bandwidth hydrophones. The material damage from several metallic materials is detected in situ and quantified ex-situ via scanning electron microscopy and confocal profilometry. With this knowledge, approaches to mitigate cavitation erosion or to even enhance the energy focusing are within reach.     

An investigation on erosion behavior of HVOF sprayed WC-CoCr coatings

Present work is an investigation of slurry erosion behavior of WC-CoCr cermet coatings deposited with two different WC grain sizes. HVOF thermal spray process was employed due to its high velocity and low flame temperature characteristics resulting in quality coating. HVOF spraying was assisted with in-flight particle temperature and velocity measurement system to control its heating. Slurry erosion testing was performed using a pot-type slurry erosion tester to evaluate slurry erosion resistance of the coatings. Two parameters were considered for testing viz. erodent particle size and slurry concentration. Surface morphology was examined using SEM images and phase identification was done by XRD. The erosion behavior and mechanism of material removal was studied and discussed based on microstructural examination. It was observed that WC-CoCr cermet coating deposited with fine grain WC exhibits higher slurry erosion resistance under all testing conditions as compared to conventional cermet coating.     

Positron annihilation study of the micro-defects induced by cavitation in mild steel

Cavitation-induced micro-defects in mild steel after cavitation experiment in the fluid field have been studied by positron Doppler broadening measurement and positron annihilation lifetime spectra (PALS). Depth-resolved positron Doppler S-parameter (DPDS) results showed that S-parameter increased and micro-defects between the surface and the bulk has obvious variation with depth during the cavitation process. From the positron lifetime results, it was found that the size and number of micro-defects increase with the development of cavitation. These results suggest that more micro-defects are generated in mild steel bulk during the cavitation process than those in the mild steel surface layer region, although more mico-defects seen in the mild steel surface layer. Moreover, the size of micro-defects in mild steel bulk increases remarkably owing to their transfer and aggregation.     

Exceptionally high cavitation erosion and corrosion resistance of a high entropy alloy

Cavitation erosion and corrosion of structural materials are serious concerns for marine and offshore industries. Durability and performance of marine components are severely impaired due to degradation from erosion and corrosion. Utilization of advanced structural materials can play a vital role in limiting such degradation. High entropy alloys (HEAs) are a relatively new class of advanced structural materials with exceptional properties. In the present work, we report on the cavitation erosion behavior of Al_0.1CoCrFeNi HEA in two different media: distilled water with and without 3.5 wt% NaCl. For comparison, conventionally used stainless steel SS316L was also evaluated in identical test conditions. Despite lower hardness and yield strength, the HEA showed significantly longer incubation period and lower erosion-corrosion rate (nearly 1/4th) compared to SS316L steel. Enhanced erosion resistance of HEA was attributed to its high work-hardening behavior and stable passivation film on the surface. The Al_0.1CoCrFeNi HEA showed lower corrosion current density, high pitting resistance and protection potential compared to SS316L steel. Further, HEA showed no evidence of intergranular corrosion likely due to the absence of secondary precipitates. Although, the degradation mechanisms (formation of pits and fatigue cracks) were similar for both the materials, the damage severity was found to be much higher for SS316L steel compared to HEA.