Designing and characterizing a multi-stepped ultrasonic horn for enhanced sonochemical performance

The commonly used ultrasonic horn generates localized cavitation below its converging tip resulting in a dense bubble cloud near the tip and limiting diffusion of reactive components into the bubble cloud or reactive radicals out of the bubble cloud. To improve contact between reactive components, a novel ultrasonic horn design was developed based on the principles of the dynamic wave equation. The horn, driven at 20 kHz, has a multi-stepped design with a cone-shaped tip increasing the energy-emitting surface areas and creating multiple reactive zones. Through different physical and chemical experiments, performance of the horn was compared to a typical horn driven at 20 kHz. Hydrophone measurements showed high acoustic pressure areas around the horn neck and tip. Sonochemiluminescence experiments verified multiple cavitation zones consistent with hydrophone readings. Calorimetry and dosimetry results demonstrated a higher energy efficiency (31.3%) and a larger hydroxyl radical formation rate constant (0.36 μM min⁻¹) compared to typical horns. In addition, the new horn degraded naphthalene faster than the typical horn tested. The characterization results demonstrate that the multi-stepped horn configuration has the potential to improve the performance of ultrasound as an advanced oxidation technology by increasing the cavitation zone in the solution.     

Sonochemical characterisation of ultrasonic dental descalers

An ultrasonic dental descaling instrument has been characterised using sonochemical techniques. Mapping the emission from luminol solution revealed the distribution of cavitation produced in water around the tips. Hydroxyl radical production rates arising from water sonolysis were measured using terephthalate dosimetry and found to be in the range of μmol min⁻¹, comparable with those from a sonochemical horn. Removal of an ink coating from a glass slide showed that cleaning occurred primarily where the tip contacted the surface but was also observed in regions where cavitation occurred even when the tip did not contact the surface. Differences in behaviour were noted between different tip designs and computer simulation of the acoustic pressure distributions using COMSOL showed the reasons behind the different behaviour of the tip designs.     

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.     

Dependence of cavitation,chemical effect,and mechanical effect thresholds on ultrasonic frequency

Cavitation, chemical effect, and mechanical effect thresholds were investigated in wide frequency ranges from 22 to 4880 kHz. Each threshold was measured in terms of sound pressure at fundamental frequency. Broadband noise emitted from acoustic cavitation bubbles was detected by a hydrophone to determine the cavitation threshold. Potassium iodide oxidation caused by acoustic cavitation was used to quantify the chemical effect threshold. The ultrasonic erosion of aluminum foil was conducted to estimate the mechanical effect threshold. The cavitation, chemical effect, and mechanical effect thresholds increased with increasing frequency. The chemical effect threshold was close to the cavitation threshold for all frequencies. At low frequency below 98 kHz, the mechanical effect threshold was nearly equal to the cavitation threshold. However, the mechanical effect threshold was greatly higher than the cavitation threshold at high frequency. In addition, the thresholds of the second harmonic and the first ultraharmonic signals were measured to detect bubble occurrence. The threshold of the second harmonic approximated to the cavitation threshold below 1000 kHz. On the other hand, the threshold of the first ultraharmonic was higher than the cavitation threshold below 98 kHz and near to the cavitation threshold at high frequency.     

Realization of cavitation fields based on the acoustic resonance modes in an immersion-type sonochemical reactor

Different modes of cavitation zones in an immersion-type sonochemical reactor have been realized based on the concept of acoustic resonance fields. The reactor contains three main components, namely a Langevin-type piezoelectric transducer (20 kHz), a metal horn, and a circular cylindrical sonicated cell filled with tap water. In order to diminish the generation of cavitation bubbles near the horn-tip, an enlarged cone-shaped horn is designed to reduce the ultrasonic intensity at the irradiating surface and to get better distribution of energy in the sonicated cell. It is demonstrated both numerically and experimentally that the cell geometry and the horn position have prominent effects on the pressure distribution of the ultrasound in the cell. With appropriate choices of these parameters, the whole reactor works at a resonant state. Several acoustic resonance modes observed in the simulation are realized experimentally to generate a large volume of cavitation zones using a very low ultrasonic power.     

Generation and control of acoustic cavitation structure

The generation and control of acoustic cavitation structure are a prerequisite for application of cavitation in the field of ultrasonic sonochemistry and ultrasonic cleaning. The generation and control of several typical acoustic cavitation structures (conical bubble structure, smoker, acoustic Lichtenberg figure, tailing bubble structure, jet-induced bubble structures) in a 20–50 kHz ultrasonic field are investigated. Cavitation bubbles tend to move along the direction of pressure drop in the region in front of radiating surface, which are the premise and the foundation of some strong acoustic cavitation structure formation. The nuclei source of above-mentioned acoustic cavitation structures is analyzed. The relationship and mutual transformation of these acoustic cavitation structures are discussed.     

Measuring derived acoustic power of an ultrasound surgical device in the linear and nonlinear operating modes

Objective and motivationThe method for measuring derived acoustic power of an ultrasound point source in the form of a sonotrode tip has been considered in the free acoustic field, according to the IEC 61847 standard. The main objective of this work is measuring averaged pressure magnitude spatial distribution of an sonotrode tip in the free acoustic field conditions at different electrical excitation levels and calculation of the derived acoustic power at excitation frequency (f₀ ≈ 25 kHz). Finding the derived acoustic power of an ultrasonic surgical device in the strong cavitation regime of working, even in the considered laboratory conditions (anechoic pool), will enable better understanding of the biological effects on the tissue produced during operation with the considered device.Experimental methodThe pressure magnitude spatial distribution is measured using B&;K 8103 hydrophone connected with a B&;K 2626 conditioning amplifier, digital storage oscilloscope LeCroy Waverunner 474, where pressure waveforms in the field points are recorded. Using MATLAB with DSP processing toolbox, averaged power spectrum density of recorded pressure signals in different field positions is calculated. The measured pressure magnitude spatial distributions are fitted with the appropriate theoretical models.Theoretical approachesIn the linear operating mode, using the acoustic reciprocity principle, the sonotrode tip is theoretically described as radially oscillating sphere (ROS) and transversely oscillating sphere (TOS) in the vicinity of pressure release boundary. The measured pressure magnitude spatial distribution is fitted with theoretical curves, describing the pressure field of the considered theoretical models. The velocity and displacement magnitudes with derived acoustic power of equivalent theoretical sources are found, and the electroacoustic efficiency factor is calculated. When the transmitter is excited at higher electrical power levels, the displacement magnitude of sonotrode tip is increased, and nonlinear behaviour in loading medium appears, with strong cavitation activity produced hydrodynamically. The presence of harmonics, subharmonics and ultraharmonics as a consequence of stable cavitation is evident in the averaged power spectral density. The cavitation noise with continuous frequency components is present as a consequence of transient cavitation. The averaged pressure magnitude at the frequency components of interest (discrete and continous) in the field points is found by calculating average power spectral density of the recorded pressure waveform signal using the welch method. The frequency band of interest where average power spectral density is calculated is in the range from 15 Hz up to 120 kHz due to measurement system restrictions. The novelty in the approach is the application of the acoustic reciprocity principle on the nonlinear system (sonotrode tip and bubble cloud) to find neccessary acoustic power of the equivalent acoustic source to produce the measured pressure magnitude in the field points at the frequency components of interest.ResultsIn the nonlinear operating mode, the ROS model for the considered sonotrode tip is chosen due to the better agreement between measurement results and theoretical considerations. At higher excitation levels, it is shown that the averaged pressure magnitude spatial distribution of discrete frequency components, produced due to stable cavitation, can be fitted in the far field with the inverse distance law. The reduced electroacoustic efficiency factor, calculated at excitation frequency component as ratio of derived acoustic power with applied electrical power, is reduced from 40% in the linear to 3% in the strong nonlinear operating mode. The derived acoustic power at other frequency components (subharmonic, harmonic and ultraharmonic) is negligible in comparison with the derived acoustic power at excitation frequency.Discussion and conclusionsThe sonotrode tip and loading medium are shown in the strong cavitation regime as the coupled nonlinear dynamical system radiating acoustic power at frequency components appearing in the spectrum. The bubble cloud in the strong nonlinear operating mode decreases the derived acoustic power significantly at the excitation frequency.     

Synchrotron quantification of ultrasound cavitation and bubble dynamics in Al–10Cu melts

Knowledge of the kinetics of gas bubble formation and evolution under cavitation conditions in molten alloys is important for the control casting defects such as porosity and dissolved hydrogen. Using in situ synchrotron X-ray radiography, we studied the dynamic behaviour of ultrasonic cavitation gas bubbles in a molten Al–10 wt% Cu alloy. The size distribution, average radius and growth rate of cavitation gas bubbles were quantified under an acoustic intensity of 800 W/cm² and a maximum acoustic pressure of 4.5 MPa (45 atm). Bubbles exhibited a log-normal size distribution with an average radius of 15.3 ± 0.5 μm. Under applied sonication conditions the growth rate of bubble radius, R(t), followed a power law with a form of R(t) = αt^β, and α = 0.0021 & β = 0.89. The observed tendencies were discussed in relation to bubble growth mechanisms of Al alloy melts.     

Visualization and optimization of cavitation activity at a solid surface in high frequency ultrasound fields

Despite the increasing use of high frequency ultrasound in heterogeneous reactions, knowledge about the spatial distribution of cavitation bubbles at the irradiated solid surface is still lacking. This gap hinders controllable surface sonoreactions. Here we present an optimization study of the cavitation bubble distribution at a solid sample using sonoluminescence and sonochemiluminescence imaging. The experiments were performed at three ultrasound frequencies, namely 580, 860 and 1142 kHz. We found that position and orientation of the sample to the transducer, as well as its material properties influence the distribution of active cavitation bubbles at the sample surface in the reactor. The reason is a significant modification of the acoustic field due to reflections and absorption of the ultrasonic wave by the solid. This is retraced by numerical simulations employing the Finite Element Method, yielding reasonable agreement of luminescent zones and high acoustic pressure amplitudes in 2D simulations. A homogeneous coverage of the test sample surface with cavitation is finally reached at nearly vertical inclination with respect to the incident wave.     

Analysis of the effect of impact of near-wall acoustic bubble collapse micro-jet on Al 1060

The bubble collapse near a wall will generate strong micro-jet in a liquid environment under ultrasonic field. To explore the effect of the impact of near-wall acoustic bubble collapse micro-jet on an aluminum 1060 sheet, the cavitation threshold formula and micro-jet velocity formula were first proposed. Then the Johnson-Cook rate correlation material constitutive model was considered, and a three-dimensional fluid-solid coupling model of micro-jet impact on a wall was established and analyzed. Finally, to validate the model, ultrasonic cavitation test and inversion analysis based on the theory of spherical indentation test were conducted. The results show that cavitation occurs significantly in the liquid under ultrasonic field, as the applied ultrasonic pressure amplitude is much larger than liquid cavitation threshold. Micro pits appear on the material surface under the impact of micro-jet. Pit depth is determined by both micro-jet velocity and micro-jet diameter, and increases with their increase. Pit diameter is mainly related to the micro-jet diameter and d_p/d_j ≈ 0.95–1.2, while pit’s diameter-to-depth ratio is mainly negatively correlated with the micro-jet velocity. Wall pressure distribution is mostly symmetric and its maximum appears on the edge of micro-jet impingement. Obviously, the greater the micro-jet velocity is, the greater the wall pressure is. Micro pits formed after the impact of micro-jet on aluminum 1060 surface were assessed by ultrasonic cavitation test. Inversion analysis results indicate that equivalent stress, equivalent strain of the pit and impact strength, and velocity of the micro-jet are closely related with pit’s diameter-to-depth ratio. For the pit’s diameter-to-depth ratio of 16–68, the corresponding micro-jet velocity calculated is 310–370 m/s.     

Precise spatial control of cavitation erosion in a vessel phantom by using an ultrasonic standing wave

In atherosclerotic inducement in animal models, the conventionally used balloon injury is invasive, produces excessive vessel injuries at unpredictable locations and is inconvenient in arterioles. Fortunately, cavitation erosion, which plays an important role in therapeutic ultrasound in blood vessels, has the potential to induce atherosclerosis noninvasively at predictable sites. In this study, precise spatial control of cavitation erosion for superficial lesions in a vessel phantom was realised by using an ultrasonic standing wave (USW) with the participation of cavitation nuclei and medium-intensity ultrasound pulses. The superficial vessel erosions were restricted between adjacent pressure nodes, which were 0.87 mm apart in the USW field of 1 MHz. The erosion positions could be shifted along the vessel by nodal modulation under a submillimetre-scale accuracy without moving the ultrasound transducers. Moreover, the cavitation erosion of the proximal or distal wall could be determined by the types of cavitation nuclei and their corresponding cavitation pulses, i.e., phase-change microbubbles with cavitation pulses of 5 MHz and SonoVue microbubbles with cavitation pulses of 1 MHz. Effects of acoustic parameters of the cavitation pulses on the cavitation erosions were investigated. The flow conditions in the experiments were considered and discussed. Compared to only using travelling waves, the proposed method in this paper improves the controllability of the cavitation erosion and reduces the erosion depth, providing a more suitable approach for vessel endothelial injury while avoiding haemorrhage.     

Sonoluminescence and dynamics of cavitation bubble populations in sulfuric acid

The detailed link of liquid phase sonochemical reactions and bubble dynamics is still not sufficiently known. To further clarify this issue, we image sonoluminescence and bubble oscillations, translations, and shapes in an acoustic cavitation setup at 23 kHz in sulfuric acid with dissolved sodium sulfate and xenon gas saturation. The colour of sonoluminescence varies in a way that emissions from excited non-volatile sodium atoms are prominently observed far from the acoustic horn emitter (“red region”), while such emissions are nearly absent close to the horn tip (“blue region”). High-speed images reveal the dynamics of distinct bubble populations that can partly be linked to the different emission regions. In particular, we see smaller strongly collapsing spherical bubbles within the blue region, while larger bubbles with a liquid jet during collapse dominate the red region. The jetting is induced by the fast bubble translation, which is a consequence of acoustic (Bjerknes) forces in the ultrasonic field. Numerical simulations with a spherical single bubble model reproduce quantitatively the volume oscillations and fast translation of the sodium emitting bubbles. Additionally, their intermittent stopping is explained by multistability in a hysteretic parameter range. The findings confirm the assumption that bubble deformations are responsible for pronounced sodium sonoluminescence. Notably the observed translation induced jetting appears to serve as efficient mixing mechanism of liquid into the heated gas phase of collapsing bubbles, thus potentially promoting liquid phase sonochemistry in general.     

Incubation pit analysis and calculation of the hydrodynamic impact pressure from the implosion of an acoustic cavitation bubble

An experimental study to evaluate cavitation bubble dynamics is conducted. The aim is to predict the magnitude and statistical distribution of hydrodynamic impact pressure generated from the implosion of various individual acoustic cavitation bubbles near to a rigid boundary, considering geometrical features of the pitted area.A steel sample was subjected to cavitation impacts by an ultrasonic transducer with a 5 mm diameter probe. The pitted surface was then examined using high-precision 3D optical interferometer techniques. Only the incubation period where surface is plastically deformed without material loss is taken into account. The exposure time was adjusted in the range of 3–60 s to avoid pit overlapping and a special procedure for pit analysis and characterisation was then followed. Moreover, a high-speed camera device was deployed to capture the implosion mechanisms of cavitation bubbles near to the surface.The geometrical characteristics of single incubation pits as well as pit clusters were studied and their deformation patterns were compared. Consequently, a reverse engineering approach was applied in order the hydrodynamic impact pressure from the implosion of an individual cavitation bubble to be determined. The characteristic parameters of the cavitation implosion process such as hydrodynamic impact pressure and liquid micro-jet impact velocity as well as the hydrodynamic severity of the cavitation impacts were quantified. It was found that the length of the hypotenuse of the orthographic projections from the center of the pit, which basically represents the deformed area of the pit, increases with the hydrodynamic impact aggressiveness in a linear rate. Majority of the hydrodynamic impacts were in the range of 0.4–1 GPa while the corresponding micro-jet velocities were found to be in the range of 200–700 m/s. Outcomes of this study, contribute to further understanding the cavitation intensity from the implosion of acoustically generated bubbles and could certainly represent a significant step towards developing more accurate cavitation models.     

An experimental study on the motion of water droplets in oil under ultrasonic irradiation

The motion of a single water droplet in oil under ultrasonic irradiation is investigated with high-speed photography in this paper. First, we described the trajectory of water droplet in oil under ultrasonic irradiation. Results indicate that in acoustic field the motion of water droplet subjected to intermittent positive and negative ultrasonic pressure shows obvious quasi-sinusoidal oscillation. Afterwards, the influence of major parameters on the motion characteristics of water droplet was studied, such as acoustic intensity, ultrasonic frequency, continuous phase viscosity, interfacial tension, and droplet diameter, etc. It is found that when the acoustic intensity and frequency are 4.89 W cm⁻² and 20 kHz respectively, which are the critical conditions, the droplet varying from 250 to 300 μm in lower viscous oil has the largest oscillation amplitude and highest oscillation frequency.     

An objective comparison of commercially-available cavitation meters

With a number of cavitation meters on the market which claim to characterise fields in ultrasonic cleaning baths, this paper provides an objective comparison of a selection of these devices and establishes the extent to which their claims are met. The National Physical Laboratory’s multi-frequency ultrasonic reference vessel provided the stable 21.06 kHz field, above and below the inertial cavitation threshold, as a test bed for the sensor comparison. Measurements from these devices were evaluated in relation to the known acoustic pressure distribution in the cavitating vessel as a means of identifying the mode of operation of the sensors and to examine the particular indicator of cavitation activity which they deliver. Through the comparison with megahertz filtered acoustic signals generated by inertial cavitation, it was determined that the majority of the cavitation meters used in this study responded to acoustic pressure generated by the direct applied acoustic field and therefore tended to overestimate the occurrence of cavitation within the vessel, giving non-zero responses under conditions when there was known to be no inertial cavitation occurring with the reference vessel. This has implications for interpreting the data they provide in user applications.     

Physicochemical characterization of black seed oil-milk emulsions through ultrasonication

The ultrasonic formation of stable emulsions of a bioactive material, black seed oil, in skim milk was investigated. The incorporation of 7% of black seed oil in pasteurised homogenized skim milk (PHSM) using 20 kHz high intensity ultrasound was successfully achieved. The effect of sonication time and acoustic power on the emulsion stability was studied. A minimum process time of 8 min at an applied acoustic power of 100 W was sufficient to produce emulsion droplets stable for at least 8 days upon storage at 4 ± 2 °C, which was confirmed through creaming stability, particle size, rheology and color analysis. Partially denatured whey proteins may provide stability to the emulsion droplets and in addition to the cavitation effects of ultrasound are responsible for the production of smaller sized emulsion droplets.     

Superiority of sonochemical processing method for the synthesis of barium titanate nanocrystals in contrast to the mechanochemical approach

The results indicated that the ultrasonic sonochemistry which brings into play the acoustic cavitation phenomenon is more powerful and feasible in synthesizing the mixed oxides in contrast to the conventional solid-state approaches. The obtained results demonstrated that the sonochemical approach is able to obtain highly pure powder product at a much lower processing temperature of about 323 K (50 °C) in contrast to 1173 K (900 °C) which is essential for the synthesis by the mechanochemical approach. Sonochemical synthesis benefits from homogenous ordering the reactant ions (which have been dissolved in the solution mixture) into perovskite structure using ultrasonication. This indicates that the acoustic cavitation phenomenon is much more powerful and cost-effective than high energy ball milling in synthesizing nanopowders of the mixed oxide materials. Moreover, the sonochemical processing method is able to prepare the final powder products in a much shorter time by a one-step synthesis approach without the need for the successive calcination in contrast to the solid-state approach.     

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).     

Cavitation and non-cavitation regime for large-scale ultrasonic standing wave particle separation systems – In situ gentle cavitation threshold determination and free radical related oxidation

We here suggest a novel and straightforward approach for liter-scale ultrasound particle manipulation standing wave systems to guide system design in terms of frequency and acoustic power for operating in either cavitation or non-cavitation regimes for ultrasound standing wave systems, using the sonochemiluminescent chemical luminol. We show that this method offers a simple way of in situ determination of the cavitation threshold for selected separation vessel geometry. Since the pressure field is system specific the cavitation threshold is system specific (for the threshold parameter range). In this study we discuss cavitation effects and also measure one implication of cavitation for the application of milk fat separation, the degree of milk fat lipid oxidation by headspace volatile measurements. For the evaluated vessel, 2 MHz as opposed to 1 MHz operation enabled operation in non-cavitation or low cavitation conditions as measured by the luminol intensity threshold method. In all cases the lipid oxidation derived volatiles were below the human sensory detection level. Ultrasound treatment did not significantly influence the oxidative changes in milk for either 1 MHz (dose of 46 kJ/L and 464 kJ/L) or 2 MHz (dose of 37 kJ/L and 373 kJ/L) operation.     

Cavitation mapping by sonochemiluminescence with less bubble displacement induced by acoustic radiation force in a 1.2 MHz HIFU

An acoustic radiation force counterbalanced appliance was employed to map the cavitation distribution in water. The appliance was made up of a focused ultrasound transducer and an aluminum alloy reflector with the exactly same shape. They were centrosymmetry around the focus of the source transducer. Spatial–temporal dynamics of cavitation bubble clouds in the 1.2 MHz ultrasonic field within this appliance were observed in water. And they were mapped by sonochemiluminescence (SCL) recordings and high-speed photography. There were significant differences in spatial distribution and temporal evolution between normal group and counterbalanced group. The reflector could avoid bubble directional displacement induced by acoustic radiation force under certain electric power (⩽50 W). As a result, the SCL intensity in the pre-focal region was larger than that of normal group. In event of high electric power (⩾70 W), most of the bubbles were moving in acoustic streaming. When electric power decreased, bubbles kept stable and showed stripe structure in SCL images. Both stationary bubbles and moving bubbles have been captured, and exhibited analytical potential with respect to bubbles in therapeutic ultrasound.