Multiple observations of cavitation cluster dynamics close to an ultrasonic horn tip

Bubble dynamics in water close to the tip of an ultrasonic horn (～23 kHz, 3 mm diameter) have been studied using electrochemistry, luminescence, acoustics, light scattering, and high-speed imaging. It is found that, under the conditions employed, a large bubble cluster (～1.5 mm radius) exists at the tip of the horn. This cluster collapses periodically every three to four cycles of the fundamental frequency of the horn. Following the collapse of the cluster, a short-lived cloud of small bubbles (each tens of microns in diameter) was observed in the solution. Large amplitude pressure emissions are also recorded, which correlate temporally with the cluster collapse. Bursts of surface erosion (measured in real time using an electrochemical technique) and multibubble sonoluminescence emission both also occur at a subharmonic of the fundamental frequency of the horn and are temporally correlated with the bubble cluster collapse and the associated pressure wave emission.     

纵-扭复合振动模式指数型复合超声变幅杆的研究

本文对指数型纵－扭复合振动模式的复合超声变幅杆进行了理论及实验研究，该变幅杆由均匀截面直棒及指数型截面杆组成。文中推出了变幅杆中纵向振动及扭转振动的共振频率方程，通过发迹指数型变截面棒的截面变化规律，实现了同一变幅杆中纵向振动与扭转振动的同频共振。     

Degradation of 4-chloro 2-aminophenol using combined strategies based on ultrasound,photolysis and ozone

The present work investigates the degradation of 4-chloro 2-aminophenol (4C2AP), a highly toxic organic compound, using ultrasonic reactors and combination of ultrasound with photolysis and ozonation for the first time. Two types of ultrasonic reactors viz. ultrasonic horn and ultrasonic bath operating at frequency of 20 kHz and 36 kHz respectively have been used in the work. The effect of initial pH, temperature and power dissipation of the ultrasonic horn on the degradation rate has been investigated. The established optimum parameters of initial pH as 6 (natural pH of the aqueous solution) and temperature as 30 ± 2 °C were then used in the degradation studies using the combined approaches. Kinetic study revealed that degradation of 4C2AP followed first order kinetics for all the treatment approaches investigated in the present work. It has been established that US + UV + O₃ combined process was the most promising method giving maximum degradation of 4C2AP in both ultrasonic horn (complete removal) and bath (89.9%) with synergistic index as 1.98 and 1.29 respectively. The cavitational yield of ultrasonic bath was found to be eighteen times higher as compared to ultrasonic horn implying that configurations with higher overall areas of transducers would be better selection for large scale treatment. Overall, the work has clearly demonstrated that combined approaches could synergistically remove the toxic pollutant (4C2AP).     

Ultrasonic-assisted Dunlop method for natural rubber latex foam production: Effects of irradiation time on morphology and physico-mechanical properties of the foam

An ultrasonic-assisted technique was first introduced for the production of natural rubber latex foam (NRLF). The flexible elastomeric foam was formed by a liquid–solid state transformation in an aqueous media. The aim of the current research was to provide a novel strategy for fabricating NRLF using ultrasonication and the Dunlop method, as well as to simultaneously utilize irradiation events to achieve the desired foam properties. NRLFs were exposed to ultrasonication at 25 kHz at the beginning of the gelling process. The effects of irradiation times of 0, 1, 3, 5 and 7 min on the morphology, foaming behaviors, physical properties and mechanical performance of NRLFs were investigated. The results revealed that using ultrasonic irradiation, unfoamed regions and a bimodal structure, which seem to be microstructural defects in conventional NRLF, could be completely eliminated. However, excessive irradiation times of 5 min and longer appeared to affect the physico-mechanical properties of the foams in terms of transient cavitation and the unfavorable physicochemical effects of ultrasonic vibrations. As a result, the optimal ultrasonic irradiation time was found to be 3 min. Using this irradiation duration, a foam with the suitable microcellular structure achieved the most desirable properties, such as its expansion ratio (7-fold increase), foam porosity (85.7%), compression recoverability (98.7%), and tensile strength (307.3 kPa). Moreover, the foam still maintained its characteristic soft nature (hardness less than 100 N) with an indentation hardness of 71.9 N. Therefore, ultrasonic treatment introduced to the conventional Dunlop method is a potentially feasible technique since it improves the morphology and the physico-mechanical properties of NRLFs.     

The complex-mode vibration of ultrasonic vibration systems

The longitudinal-flexural and torsional-flexural vibrations are studied for the ultrasonic solid horn and the ultrasonic vibration system comprised of a sandwich transducer and a solid horn. The discussed solid horn is of arbitrary non-uniform cross-section. The analysis on flexural-mode vibration is based on Timoshenko theory. The theoretical results are verified by experiment.     

Mapping of an ultrasonic horn: link primary and secondary effects of ultrasound

The erratic behaviour of cavitational activity exhibited in a sonochemical reactor pose a serious problem in the efficient design and scale-up; thus it becomes important to identify the active and passive zones existing in the reactor so as to enable proper placement of the reaction mixtures for achieving maximum benefits. In the present work mapping of ultrasonic horn has been carried with the help of local pressure measurement using a hydrophone and estimation of amount of liberated iodine using the Weissler reaction and a quantitative relationship has been established. The measured local pressure pulses have been used in the theoretical simulations of the bubble dynamics equations to check the type of cavitation taking place locally and also estimate the possible collapse pressure pulse in terms of maximum bubble size reached during the cavitation phenomena. Relationship has been also established between the observed iodine liberation rates and the maximum bubble size reached. The engineers can easily use these unique relationships in efficient design, as the direct quantification of the secondary effect is possible.     

Modeling cavitation in a rapidly changing pressure field – Application to a small ultrasonic horn

Ultrasonic horn transducers are frequently used in applications of acoustic cavitation in liquids. It has been observed that if the horn tip is sufficiently small and driven at high amplitude, cavitation is very strong, and the tip can be covered entirely by the gas/vapor phase for longer time intervals. A peculiar dynamics of the attached cavity can emerge with expansion and collapse at a self-generated frequency in the subharmonic range, i.e. below the acoustic driving frequency. The term “acoustic supercavitation” was proposed for this type of cavitation Žnidarčič et al. (2014) [1].We tested several established hydrodynamic cavitation models on this problem, but none of them was able to correctly predict the flow features. As a specific characteristic of such acoustic cavitation problems lies in the rapidly changing driving pressures, we present an improved approach to cavitation modeling, which does not neglect the second derivatives in the Rayleigh–Plesset equation. Comparison with measurements of acoustic supercavitation at an ultrasonic horn of 20 kHz frequency revealed a good agreement in terms of cavity dynamics, cavity volume and emitted pressure pulsations.The newly developed cavitation model is particularly suited for simulation of cavitating flow in highly fluctuating driving pressure fields.     

Optimization design of high power ultrasonic circular ring radiator in coupled vibration

This paper presents a new high power ultrasonic (HPU) radiator, which consists of a transducer, an ultrasonic horn, and a metal circular ring. Both the transducer and horn in longitudinal vibrations are used to drive a metal circular ring in a radial-axial coupled vibration. This coupled vibration cannot only generate ultrasound in both the radial and axial directions, but also focus the ultrasound inside the circular ring. Except for the radial-axial coupled vibration mode, the third longitudinal harmonic vibration mode with relative large vibration amplitude is also detected, which can be used as another operation mode. Overall, the HPU with these two vibration modes should have good potential to be applied in liquid processing, such as sonochemistry, ultrasonic cleaning, and Chinese herbal medicine extraction.     

Intensification of delignification of Tectona grandis saw dust as sustainable biomass using acoustic cavitational devices

Delignification of sawdust was studied using ultrasound assisted alkali peroxide approach using longitudinal horn for the first time and the efficacy compared with more commonly used configurations of ultrasonic reactors. Comparison with the conventional approach based on stirring has also been presented to establish the process intensification benefits. Effect of different operating parameters such as sodium carbonate concentration (0.1, 0.15, 0.2, 0.25 M), hydrogen peroxide concentration (0.2, 0.4, 0.6, 0.8, 1 M) and biomass loading (2, 4, 6, 8, 10 wt%), on the efficacy of lignin extraction has been investigated for different ultrasonic reactors. The optimum conditions for probe type ultrasonic horn were established as 150 W, 50% duty cycle and 80% amplitude with optimum process conditions as Na₂CO₃ concentration as 0.2 M, H₂O₂ concentration as 1 M, biomass loading of 10 wt% and operating time of 70 min. Longitudinal horn resulted in best efficacy (both in terms of yield and energy requirements) followed by ultrasonic horn and ultrasonic bath whereas the conventional approach was least effective. The obtained lignin was also analyzed using different characterization techniques. The presence of peaks at wavelength range of 875–817, 1123–1110, and at 1599 cm⁻¹ for the extracted sample confirmed the presence of lignin. Increase in the crystallinity index of the processed sample (maximum for longitudinal horn) also confirmed the lignin removal as lignin is amorphous in nature. Overall it has been concluded that ultrasound can be effectively used for delignification with longitudinal horn as best configuration.     

Precipitation of calcium carbonate by ultrasonic irradiation

Supersaturated solution of calcium carbonate ([Ca²⁺]=1.2 mmol/L, [HCO₃⁻]=3.2 mmol/L, pH=8.8, T=30±0.5 °C), a scale forming component, was irradiated by an ultrasonic homogenizer (24 kHz, 15–250 W/cm²) to study the factors that affect its precipitation rate. The factors of (1) depth of horn immersion, (2) ultrasonic intensity and horn tip size and (3) cavitation, which can affect the precipitation rate were investigated in this study. Ultrasonic irradiation was observed to accelerate the precipitation of calcium carbonate and it was found that there exists an optimum range of horn immersion depth for maximizing the precipitation rate. The experimental data also established that the precipitation rate was proportional to ultrasonic intensity and diameter of horn tip. These findings were correlated to the effects of physical mixing, that arises due to ultrasonic irradiation. However, the effect of cavitation in accelerating the precipitation rate was found to be small. Thus it is forwarded that the physical mixing effect, especially macrostreaming is the main factor that accelerates the precipitation rate of calcium carbonate during ultrasonic treatment. Further, neither the morphology nor the size of the calcium carbonate crystals formed were found to be affected by the ultrasonic irradiation.     

Influence of ultrasonic vibrations on the growth of semiconductor single crystals

The influence of ultrasonic vibrations on striations in InSb, GaAs and Bi-Sb alloy single crystals grown by a modified Czochralski method was investigated. Ultrasonic vibrations at frequencies of 0.15, 0.25, 0.6, 1.2, 2.5, 5 or 10 MHz were introduced into the melt parallel to the pulling axis. The introduction of ultrasonic vibrations at a frequency up to 5 MHz eliminates the striations in GaAs and Bi-Sb alloy single crystals growing with constant diameter. It was found that for Bi-Sb alloy single crystals of constant diameter growth, after ‘processing’ of the melt with ultrasonic vibrations, the striations do not reappear until after 2 h. The effectiveness of the influence of the ultrasonic vibrations on the decrease of growth striations in InSb, GaAs and Bi-Sb alloy growing crystals was estimated with the help of the calculation of the sound absorption coefficient.     

Generation of microbubbles from hollow cylindrical ultrasonic horn

In this study, we found that microbubbles with diameters of less than 100 μm can be easily generated by using a hollow cylindrical ultrasonic horn. Consecutive images of bubbles obtained by using high-speed and high-resolution cameras reveal that a capillary wave is formed on the gas–liquid interface under weak ultrasonic irradiation and that the wave head is detached in the form of bubbles by the fragmentation of the interface as the power of ultrasonic irradiation increases. Moreover, consecutive images of the bubble interface obtained by an ultra-high-speed camera indicate that the breakup of bubbles oscillating harmonically with the ultrasonic irradiation generates many microbubbles that are less than 100 μm in diameter. With regard to the orifice diameter of the horn end, we found that its optimum value varies with the ultrasonic power input. When the orifice diameter is small, the capillary wave generated from the horn end easily propagates all over the gas–liquid interface, thereby starting the generation of microbubbles at a lower ultrasonic power input. When the orifice diameter is large, the capillary wave is attenuated because of viscosity and surface tension. Hence, in this case, microbubble generation from the horn requires a higher ultrasonic power input. Furthermore, the maximum yield of microbubbles via primary and secondary bubble generation can be increased by increasing the gas flow rate.     

Ultrasonic bath with longitudinal vibrations: a novel configuration for efficient wastewater treatment

Efficacy of a novel configuration for large-scale wastewater treatment applications has been investigated using formic acid degradation as a model reaction. The reactor is first characterized using energy efficiency measurements and the optimum operating volume for maximum transfer of supplied energy and hence maximum cavitational effects has been established. Effect of initial concentration of the pollutant on the rates of degradation has been investigated. Comparison has been also made with the conventional ultrasonic horn in terms of energy efficiency and cavitational yield for the model reaction. With an aim of possible reduction in the total treatment time, some intensification studies have been undertaken considering hydrogen peroxide as an additional source of free radicals.     

Mixing time analysis of a sonochemical reactor

Mixing time measurements have been carried out in a cylindrical reactor irradiated with an ultrasonic horn fitted with different size tips. Liquid phase bulk velocities induced by the vibrating horn surface have been estimated from the mixing time measurements. A relationship has been established between the mean horn surface velocities (frequency x amplitude) and the mean velocities estimated from the mixing time measurements. A correlation has been developed for the prediction of the mixing time using a method similar to that used for liquid jet mixing. This could be the first step in defining the overall flow field, the information about which can then be used to get realistic numerical solutions of the Rayleigh-Plesset equation for a travelling cavity to understand the cavity dynamics in the various parts of the ultrasonic horn reactor.     

模式转换型超声塑焊振动系统的设计

基于弯曲振动理论和耦合振动理论,设计了一种新型大尺寸筒形超声塑焊振动系统。该振动系统由纵向振动换能器及变幅杆、弯曲振动金属圆盘和耦合振动圆筒四部分组成。换能器和变幅杆的纵向振动驱动圆盘的二次弯曲模式振动,圆盘的二次弯曲模式振动激励圆筒的纵向模式振动,实现了工具头在较高频率下谐振。实验结果表明,振动系统的测试频率与计算频率比较符合,在大信号下测试的纵-弯-纵振动模式转换效果很好。研究结果为高频大尺寸超声焊接系统的设计提供了思路。      

Investigation of induction of air due to ultrasound source in the sonochemical reactors

A detailed investigation into the phenomena of induction of air using a novel arrangement of the ultrasonic horn (tip is located just above the liquid surface) has been made with the quantification of the extent of induction in terms of the air entrainment rate and the gas–liquid mass transfer coefficient for the transfer of air into the system. The measurement of air entrainment rate was found to be quite difficult and hence focus was kept on the quantification in terms of the gas–liquid mass transfer coefficient. The effect of ultrasonic power dissipation and type of the liquid medium (water, sodium chloride and sodium laruyl sulphate [surfactant] solution) on the mass transfer coefficient has been studied and correlations have been developed for the prediction of the same. Comparison with the mechanically agitated surface aerators has enabled us to understand the controlling mechanism in the induction and subsequent distribution of the air i.e. turbulence or convective motion. The present work should open an entirely new field of research in the area of design of sonochemical gas–liquid reactors operating possibly as a combination of gas-inducing reactors and cavitational reactors.     

Sonochemical reaction with microbubbles generated by hollow ultrasonic horn

A microbubble generator with a cylindrical hollow ultrasonic horn (HUSH), gas flow path, and an orifice inside it can produce high ultrasonic pressure around the generated microbubbles. We used this microbubble generator with a HUSH as a sonochemical reactor for the degradation of indigo carmine and evaluated the sonochemical reaction by simply inserting the horn end into a liquid. The experimental results revealed that the ultrasonic irradiation around ultrasonically generated microbubbles effectively degraded indigo carmine in water. In addition, degradation experiments performed by varying the ultrasonic power and gas flow rates indicated that a continuous gas supply and ultrasonic pressure were required for generating the microbubbles, without the generation of millimeter-scale bubbles, to enhance the sonochemical reaction in water.     

Effect of molecular weight on the ultrasonic degradation of poly(vinyl-pyrrolidone)

The ultrasonic degradation of poly(vinyl-pyrrolidone) (PVP) of different initial molecular weights was studied at a fixed temperature. The effect of solution concentration on the rate of degradation was investigated. A method of viscometry was used to study the degradation behavior and kinetic model was developed to estimate the degradation rate constant. The results were indicated that the rate of ultrasonic degradation increased with increasing molecular weight. It was found that rate constant decreases as the concentration increases. The calculated rate constants correlated in terms of inverse concentration and relative viscosity of PVP solutions. This behavior in the rate of degradation was interpreted in terms of viscosity and concentration of polymer solution. With increasing solution concentration, viscosity increases and it causes a reduction in the cavitation efficiency thus, the rate of degradation will be decreased. The experimental results show that the viscosity of polymers decreased with ultrasonic irradiation time and approached a limiting value, below which no further degradation took place. This study confirms the general assumption that the shear forces generated by the rapid motion of the solvent following cavitational collapse are responsible for the breakage of the chemical bonds within the polymer. The effect of polymer concentration can be interpreted in terms of the increase in viscosity with concentration, causing the molecules to become less mobile in solution and the velocity gradients around the collapsing bubbles to, therefore, become smaller.     

Power ultrasound interaction with DC atmospheric pressure electrical discharge

The effect of power ultrasound application on DC hollow needle to plate atmospheric pressure electrical discharge enhanced by the flow of air through the needle electrode was studied experimentally. It was found that applying ultrasound increases discharge volume. In this volume take place plasmachemical processes, used in important ecological applications such as the production of ozone, VOC decomposition and de-NOx processes enhancement. In our experiments we used a negatively biased needle electrode as a cathode and a perpendicularly placed surface of the ultrasonic resonator--horn--as an anode. To demonstrate the effect of ultrasound waves on electrical discharge photographs of the discharge for the needle to the ultrasonic resonator at distances of 4, 6 and 8mm are shown. By varying the distance between needle and the surface of the transducer, we were able to create the node or the antinode at the region around the tip of the needle, where the ionization processes are effective. In our experimental arrangement the amplitude of acoustic pressure at antinode exceeded 10(4) Pa. The photographs reveal that the diameter of the discharge on the surface of the ultrasonic horn is increased when ultrasound is applied. The increase of discharge volume caused by the application of ultrasound can be explained as a combined effect of the change of the reduced electric field E/n (E is electric field strength and n is the neutral particles density), strong turbulence of the particles in the discharge region caused by quick changes of amplitudes of the standing ultrasonic wave and finally by the boundary layer near the ultrasonic transducer perturbations due to vibrations of the transducer surface.     

A nonrational B-spline profiled horn with high displacement amplification for ultrasonic welding

A new horn with high displacement amplification for ultrasonic welding is developed. The profile of the horn is a nonrational B-spline curve with an open uniform knot vector. The ultrasonic actuation of the horn exploits the first longitudinal displacement mode of the horn. The horn is designed by an optimization scheme and finite element analyses. Performances of the proposed horn have been evaluated by experiments. The displacement amplification of the proposed horn is 41.4% and 8.6% higher than that of the traditional catenoidal horn and a Bézier-profile horn, respectively, with the same length and end surface diameters. The developed horn has a lower displacement amplification than the nonuniform rational B-spline profiled horn but a much smoother stress distribution. The developed horn, the catenoidal horn, and the Bézier horn are fabricated and used for ultrasonic welding of lap-shear specimens. The bonding strength of the joints welded by the open uniform nonrational B-spline (OUNBS) horn is the highest among the three horns for the various welding parameters considered. The locations of the failure mode and the distribution of the voids of the specimens are investigated to explain the reason of the high bonding strength achieved by the OUNBS horn.