Hypocrellin B-mediated sonodynamic action induces apoptosis of hepatocellular carcinoma cells

Objective

The present study aims to investigate apoptosis of hepatocellular carcinoma cells induced by hypocrellin B-mediated sonodynamic action.

Methods

The hypocrellin B concentration was kept constant at 2.5 μM and cells from the hepatocellular carcinoma HepG2 cell line were exposed to ultrasound with an intensity of 0.46 W/cm² for 8 s. Cell cytotoxicity was quantified using an MTT assay 24 h after sonodynamic therapy (SDT) of hypocrellin B. Apoptosis was investigated using a flow cytometry with Annexin V-FITC and propidium iodine staining. Intracellular reactive oxygen species (ROS) levels were detected using a flow cytometry with 2,7-dichlorodihydrofluorecein diacetate (DCFH-DA) staining.

Results

The cytotoxicity of hypocrellin B-mediated sonodynamic action on HepG2 cells was significantly higher than those of other treatments including ultrasound alone, hypocrellin B alone and sham treatment. Flow cytometry showed that hypocrellin B-induced sonodynamic action markedly enhanced the apoptotic rate of HepG2 cells. Increased ROS was observed in HepG2 cells after being treated with hypocrellin B-mediated sonodynamic action.

Conclusions

Our data demonstrated that hypocrellin B-mediated sonodynamic action remarkably induced apoptosis of HepG2 cells, suggesting that apoptosis is an important mechanism of cell death induced by hypocrellin B-mediated SDT.     

Stabilizing in vitro ultrasound-mediated gene transfection by regulating cavitation

It is well known that acoustic cavitation can facilitate the inward transport of genetic materials across cell membranes (sonoporation). However, partially due to the unstationary behavior of the initiation and leveling of cavitation, the sonoporation effect is usually unstable, especially in low intensity conditions. A system which is able to regulate the cavitation level during sonication by modulating the applied acoustic intensity with a feedback loop is implemented and its effect on in vitro gene transfection is tested. The regulated system provided better time stability and reproducibility of the cavitation levels than the unregulated conditions. Cultured hepatoma cells (BNL) mixed with 10 μg luciferase plasmids are exposed to 1-MHz pulsed ultrasound with or without cavitation regulation, and the gene transfection efficiency and cell viability are subsequently assessed. Experimental results show that for all exposure intensities (low, medium, and high), stable and intensity dependent, although not higher, gene expression could be achieved in the regulated cavitation system than the unregulated conditions. The cavitation regulation system provides a better control of cavitation and its bioeffect which are crucial important for clinical applications of ultrasound-mediated gene transfection.     

Promoting inertial cavitation by nonlinear frequency mixing in a bifrequency focused ultrasound beam

Enhancing cavitation activity with minimal acoustic intensities could be interesting in a variety of therapeutic applications where mechanical effects of cavitation are needed with minimal heating of surrounding tissues. The present work focuses on the relative efficiency of a signal combining two neighbouring frequencies and a one-frequency signal for initiating ultrasound inertial cavitation. Experiments were carried out in a water tank, using a 550 kHz piezoelectric composite spherical transducer focused on targets with 46 μm roughness. The acoustic signal scattered, either by the target or by the cavitation bubbles, is filtered using a spectral and cepstral-like method to obtain an inertial cavitation activity measurement. The ultrasound excitations consist of 1.8 ms single bursts of single frequency f₀ = 550 kHz excitation, in the monofrequency case, and of dual frequency f₁ = 535 kHz and f₂ = 565 kHz excitation, in the bifrequency case. It is shown that depending on the value of the monofrequency cavitation threshold intensity the bifrequency excitation can increase or reduce the cavitation threshold. The analysis of the thresholds indicates that the mechanisms involved are nonlinear. The progress of the cavitation activity beyond the cavitation threshold is also studied. The slope of the cavitation activity considered as a function of the acoustic intensity is always steeper in the case of the bifrequency excitation. This means that the delimitation of the region where cavitation occurs should be cleaner than with a classical monofrequency excitation.     

Removal of bacteria Legionella pneumophila,Escherichia coli,and Bacillus subtilis by (super)cavitation

In sufficient concentrations, the pathogenic bacteria L. pneumophila can cause a respiratory illness that is known as the “Legionnaires” disease. Moreover, toxic Shiga strains of bacteria E. coli can cause life-threatening hemolytic-uremic syndrome. Because of the recent restrictions imposed on the usage of chlorine, outbreaks of these two bacterial species have become more common. In this study we have developed a novel rotation generator and its effectiveness against bacteria Legionella pneumophila and Escherichia coli was tested for various types of hydrodynamic cavitation (attached steady cavitation, developed unsteady cavitation and supercavitation). The results show that the supercavitation was the only effective form of cavitation. It enabled more than 3 logs reductions for both bacterial species and was also effective against a more persistent Gram positive bacteria, B. subtilis. The deactivation mechanism is at present unknown. It is proposed that when bacterial cells enter a supercavitation cavity, an immediate pressure drop occurs and this results in bursting of the cellular membrane. The new rotation generator that induced supercavitation proved to be economically and microbiologically far more effective than the classical Venturi section (super)cavitation.     

Sonodynamic therapy combined with novel anti-cancer agents,sanguinarine and ginger root extract: Synergistic increase in toxicity in the presence of PANC-1 cells in vitro

The presence of ultrasound-induced cavitation in sonodynamic therapy (SDT) treatments has previously enhanced the activity and delivery of certain sonosensitisers in biological systems. The purpose of this work was to investigate the potential for two novel anti-cancer agents from natural derivatives, sanguinarine and ginger root extract (GRE), as sonosensitisers in an SDT treatment with in vitro PANC-1 cells. Both anti-cancer compounds had a dose-dependent cytotoxicity in the presence of PANC-1 cells. A range of six discreet ultrasound power-frequency configurations were tested and it was found that the cell death caused directly by ultrasound was likely due to the sonomechanical effects of cavitation. Combined treatment used dosages of 100 μM sanguinarine or 1 mM of GRE with 15 s sonication at 500 kHz and 10 W. The sanguinarine-SDT and GRE-SDT treatments showed a 6% and 17% synergistic increase in observed cell death, respectively. Therefore both sanguinarine and GRE were found to be effective sonosensitisers and warrant further development for SDT, with a view to maximising the magnitude of synergistic increase in toxicity.     

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.     

Evaluation of ultrasound and microbubbles effect on pork meat during brining process

In this study combined effect of ultrasound-induced acoustic cavitation and microbubbles during meat brining on pork loin (Longissimus dorsi) was evaluated. Cylindrical shape (diameter 15 mm, height 80 mm) pork loin samples were cut and immersed in 200 g L^-1 NaCl brine and treated with the following brining methods for 180 min: static brining (SB), ultrasound assisted brining (US) and ultrasound combined with microbubbles in brine (USMB). Ultrasound was generated with 20 kHz frequency, 5,09 W/cm² maximum intensity and 100 W maximum power. Microbubbles in brine were produced by a gas–liquid mixing pump. Effect of ultrasound and microbbubles on NaCl content and diffusion in pork loin, mass balance, water binding capacity (WBC), protein denaturation and meat tissue microstructure were evaluated. The US and USMB brinings enhanced the NaCl diffusion into meat compared to meat brined under static conditions. The constant diffusion coefficient (D) model precisely described the NaCl diffusion kinetics during brinings. The ultrasound and microbbubles resulted in microscopic pores on the surface of myofibers. Decreasing WBC was observed for all brining methods. Myosin was not detectable in any of the brining methods. Denaturation temperature of actin showed a decreasing tendency with increasing brining time independently the brining methods.     

Apoptosis of ovarian cancer cells induced by methylene blue-mediated sonodynamic action

Objective

The present study aims to investigate apoptosis of ovarian cancer cells induced by methylene blue (MB)-mediated sonodynamic therapy (SDT).

Methods

The MB concentration was kept constant at 100 μM and ovarian cancer HO-8910 cells were exposed to ultrasound therapy for 5 s with an intensity of 0.46 W/cm². The cytotoxicity was investigated 24 h after MB-mediated sonodynamic action. Apoptosis was analyzed using a flow cytometer with Annexin V-FITC and propidium iodine (PI) staining as well as fluorescence microscopy with Hoechst 33258 staining. Intracellular reactive oxygen species (ROS) level was measured by flow cytometer with 2,7-dichlorodihydrofluorescein diacetate (DCFH-DA) staining.

Results

The cytotoxicity of MB-mediated SDT on HO-8910 cells after MB-mediated SDT was significantly higher than those of other treatments including ultrasound alone, MB alone and sham treatment. Flow cytometric analysis showed a significant increase in the early and late apoptotic cell populations by MB-mediated SDT of HO-8910 cells. Nuclear condensation and increased ROS levels were also found in HO-8910 cells treated by MB-mediated SDT.

Conclusions

Our findings demonstrated that MB-mediated sonodynamic action significantly induced apoptosis of HO-8910 cells and an increase in intracellular ROS level. This indicates that apoptosis is an important mechanism of cell death induced by MB-mediated SDT. Thus, MB-mediated SDT might be a potential therapeutic strategy for combating ovarian cancer.     

Insights into the novel application of Fe-MOFs in ultrasound-assisted heterogeneous Fenton system: Efficiency,kinetics and mechanism

In this work, as a new strategy, ultrasound/H₂O₂/MOF system was firstly applied by environmental-benign Fe-MOFs (MIL-53, MIL-88B and MIL-101) for tetracycline hydrochloride removal. The synthetic Fe-MOFs were characterized by XRD, FTIR, SEM, XPS, N₂ sorption-desorption isotherms and CO-FTIR. MIL-88B demonstrated the best catalytic performance because of its highest amount of Lewis acid sites. Influencing factors, contrast experiment, and corresponding dynamics were carried out to obtain the best experimental conditions and reaction system. Under optimal conditions ([Tetracycline hydrochloride] = 10 mg/L, [MIL-88B] = 0.3 g/L, [H₂O₂] = 44 mM, [ultrasound power] = 60 W, and pH = 5.0), the-first-order kinetic rate constant k was calculated to be 0.226 min⁻¹, higher than the simple combination of the ultrasound system (0.004) and MIL-88B/H₂O₂ system (0.163), indicating the importance of synergistic effect between ultrasound and Fenton reaction. EPR test and quenching experiment proved that ·OH is mainly responsible for tetracycline hydrochloride removal. The major reaction path is the adsorption and decomposition of H₂O₂ by coordinative unsaturated iron sites on Fe-MOF, but it is not the only path. The direct decomposition of H₂O₂ and the cavitation effect caused by ultrasound also contribute to the generation of OH.     

Effect of exposure parameters on cavitation induced by low-level dual-frequency ultrasound

In order to quantify the effects of exposure parameters under therapeutic conditions such as sonodynamic therapy, it is necessary initially to evaluate the inertial cavitation activity in vitro. In this study, the dependence of cavitation activity induced by the low-level dual-frequency ultrasound irradiation on exposure parameters has been studied. Experiments were performed in the near 150 kHz and 1 MHz fields in the progressive wave mode. It has been shown that at constant ultrasound energy the fluorescence intensity for continuous sonication is higher than for pulsed mode. With increasing the duty cycle of pulsed field, the inertial cavitation activity is increased. The activity of cavitation produced by simultaneous combined sonication by two ultrasound fields is remarkably higher than the algebraic sum of effects produced by fields separately (p-value < 0.05). This study shows that simultaneous combined dual-frequency ultrasound sonication in continuous mode is more effective in producing inertial cavitation activity at low-level intensity. Therefore, it is concluded that investigations in this combined ultrasound sonication can be useful in sonodynamic therapy for superficial tumors.     

Sonodynamic action of pyropheophorbide-a methyl ester induces mitochondrial damage in liver cancer cells

Sonodynamic therapy with pyropheophorbide-a methyl ester (MPPa) presents a promising aspect in treating liver cancer. The present study aims to investigate the mitochondrial damage of liver cancer cells induced by MPPa-mediated sonodynamic action. Mouse hepatoma cell line H₂₂ cells were incubated with MPPa (2 μM) for 20 h and then exposed to ultrasound with an intensity of 0.97 W/cm² for 8 s. Cytotoxicity was investigated 24 h after sonodynamic action using MTT assay and light microscopy. Mitochondrial membrane potential (ΔΨm) was analyzed using flow cytometry with rhodamine 123 staining and ultrastructural changes were observed using transmission electron microscopy (TEM).The cytotoxicity of MPPa-mediated SDT on H₂₂ cell line was 73.00 ± 3.42%, greater than ultrasound treatment alone (28.12 ± 5.19%) significantly while MPPa treatment alone had no significant effect on H₂₂ cells. Moreover, after MPPa-mediated SDT cancer cells showed swollen mitochondria under TEM and a significant collapse of mitochondrial membrane potential. Our findings demonstrated that MPPa-mediated SDT could remarkably induce cell death of H₂₂ cells, and highlighted that mitochondrial damage might be an important cause of cell death induced by MPPa-mediated SDT.     

Detection of sonoluminescence signals in a gel phantom in the presence of Protoporphyrin IX conjugated to gold nanoparticles

The particles in a liquid decrease the ultrasonic intensity threshold required for cavitation onset. In this study, a new nanoconjugate composed of Protoporphyrin IX and gold nanoparticles (Au–PpIX) was used as a nucleation site for cavitation. The nonradiative relaxation time of Protoporphyrin IX in the presence of gold nanoparticles is longer than the similar time without gold nanoparticles. The acoustic cavitation activity was investigated via recording of the integrated sonoluminescence signal in the wavelength range of 220–700 nm in a gel phantom by a cooled charge coupled device (CCD) at different intensities of 1 MHz ultrasound. In order to confirm these results, a chemical dosimetric method was utilized, too. The recorded sonoluminescence signal in the gel phantom containing Au–PpIX was higher than the other phantoms. These records have been confirmed by the chemical dosimetric data. Therefore, we anticipate that a new nanoconjugate composed of Protoporphyrin IX and gold nanoparticles can act as an efficient sonoluminescence agent and could be introduced as a novel sonosensitizer for sonodynamic therapy.     

Ultrasound energy to accelerate dye uptake and dye–fiber interaction of reactive dye on knitted cotton fabric at low temperatures

Acoustic cavitation formed due to propagation of ultrasound wave inside a dye bath was successfully used to dye cotton fabric with a reactive dye at lower temperatures. The energy input to the system during sonication was 0.7 W/cm². This was within the energy range that contributes towards forming cavitation during ultra-sonication. The influence of ultrasound treatment on dye particle size and fiber morphology is discussed. Particle size analysis of the dye bath revealed ultra-sonication energy was capable of de-agglomeration of hydrolyzed dye molecules during dyeing. SEM micrograph and AFM topographical image of the fiber surface revealed fiber morphology remains unchanged after the sonication. The study was extended in understanding the contribution of ultrasound method of dyeing towards achieving good color strength on the fabric, compared to the normal heating method of dyeing. Study showed color strength obtained using ultra sound method of dyeing is higher compared to normal heating dyeing. Ultrasound energy was able to achieve the good color strength on cotton fabric at very low temperature such as 30 °C, which was approximately 230% more than the color strength achieved in normal heating method of dyeing. This indicates that energy input to the system using ultrasound was capable of acting as an effective alternative method of dyeing knitted cotton fabrics with reactive dye.     

Sonodynamic therapy using water-dispersed TiO2-polyethylene glycol compound on glioma cells: comparison of cytotoxic mechanism with photodynamic therapy

Sonodynamic therapy is expected to be a novel therapeutic strategy for malignant gliomas. The titanium dioxide (TiO(2)) nanoparticle, a photosensitizer, can be activated by ultrasound. In this study, by using water-dispersed TiO(2) nanoparticles, an in vitro comparison was made between the photodynamic and sonodynamic damages on U251 human glioblastoma cell lines. Water-dispersed TiO(2) nanoparticles were constructed by the adsorption of chemically modified polyethylene glycole (PEG) on the TiO(2) surface (TiO(2)/PEG). To evaluate cytotoxicity, U251 monolayer cells were incubated in culture medium including 100 μg/ml of TiO(2)/PEG for 3h and subsequently irradiated by ultraviolet light (5.0 mW/cm(2)) or 1.0MHz ultrasound (1.0 W/cm(2)). Cell survival was estimated by MTT assay 24h after irradiation. In the presence of TiO(2)/PEG, the photodynamic cytotoxic effect was not observed after 20 min of an ultraviolet light exposure, while the sonodynamic cytotoxicity effect was almost proportional to the time of sonication. In addition, photodynamic cytotoxicity of TiO(2)/PEG was almost completely inhibited by radical scavenger, while suppression of the sonodynamic cytotoxic effect was not significant. Results of various fluorescent stains showed that ultrasound-treated cells lost their viability immediately after irradiation, and cell membranes were especially damaged in comparison with ultraviolet-treated cells. These findings showed a potential application of TiO(2)/PEG to sonodynamic therapy as a new treatment of malignant gliomas and suggested that the mechanism of TiO(2)/PEG mediated sonodynamic cytotoxicity differs from that of photodynamic cytotoxicity.     

Mapping of cavitational activity in a pilot plant dyeing equipment

A large number of papers of the literature quote dyeing intensification based on the application of ultrasound (US) in the dyeing liquor. Mass transfer mechanisms are described and quantified, nevertheless these experimental results in general refer to small laboratory apparatuses with a capacity of a few hundred millilitres and extremely high volumetric energy intensity. With the strategy of overcoming the scale-up inaccuracy consequent to the technological application of ultrasounds, a dyeing pilot-plant prototype of suitable liquor capacity (about 40 L) and properly simulating several liquor to textile hydraulic relationships was designed by including US transducers with different geometries.Optimal dyeing may be obtained by optimising the distance between transducer and textile material, the liquid height being a non-negligible operating parameter. Hence, mapping the cavitation energy in the machinery is expected to provide basic data on the intensity and distribution of the ultrasonic field in the aqueous liquor. A flat ultrasonic transducer (absorbed electrical power of 600 W), equipped with eight devices emitting at 25 kHz, was mounted horizontally at the equipment bottom.Considering industrial scale dyeing, liquor and textile substrate are reciprocally displaced to achieve a uniform colouration. In this technology a non uniform US field could affect the dyeing evenness to a large extent; hence, mapping the cavitation energy distribution in the machinery is expected to provide fundamental data and define optimal operating conditions. Local values of the cavitation intensity were recorded by using a carefully calibrated Ultrasonic Energy Meter, which is able to measure the power per unit surface generated by the cavitation implosion of bubbles. More than 200 measurements were recorded to define the map at each horizontal plane positioned at a different distance from the US transducer; tap water was heated at the same temperature used for dyeing tests (60 °C). Different liquid flow rates were tested to investigate the effect of the hydrodynamics characterising the equipment.The mapping of the cavitation intensity in the pilot-plant machinery was performed to achieve with the following goals: (a) to evaluate the influence of turbulence on the cavitation intensity, and (b) to determine the optimal distance from the ultrasound device at which a fabric should be positioned, this parameter being a compromise between the cavitation intensity (higher next to the transducer) and the US field uniformity (achieved at some distance from this device).By carrying out dyeing tests of wool fabrics in the prototype unit, consistent results were confirmed by comparison with the mapping of cavitation intensity.     

Targeted and ultrasound-triggered drug delivery using liposomes co-modified with cancer cell-targeting aptamers and a thermosensitive polymer

In this study, we demonstrated the feasibility of targeted and ultrasound-triggered drug delivery using liposomes co-modified with single stranded DNA aptamers that recognized platelet-derived growth factor receptors (PDGFRs) as targeting ligands for breast cancer cells and poly(NIPMAM-co-NIPAM) as the thermosensitive polymer (TSP) to sensitize these liposomes to high temperature. TSP-modified liposomes (TSP liposomes) released encapsulated calcein under 1 MHz ultrasound irradiation for 30 s at 0.5 W/cm² as well as the case under incubation for 5 min at 42 °C. Ultrasound-triggered calcein release from TSP liposomes was due to an increased local temperature, resulting from cavitation bubble collapse induced by ultrasound, and not due to an increase in the bulk medium temperature. Liposomes modified with PDGFR aptamers (APT liposomes) bound to MDA-MB-231 human breast cancer cells through PDGFR aptamers; however, they did not bind to primary human mammary epithelial cells (HMECs). The binding of APT liposomes was greatest for MDA-MB-231 cells, followed by MCF-7, WiDr, and HepG2 cancer cells. In a cell injury assay using doxorubicin (DOX)-loaded APT/TSP liposomes and ultrasound irradiation, cell viability of MDA-MB-231 at 24 h after ultrasound irradiation (1 MHz for 30 s at 0.5 W/cm²) with DOX-loaded APT/TSP liposomes was 60%, which was lower than that with ultrasound irradiation and DOX-loaded TSP liposomes or with DOX-loaded APT/TSP liposomes alone.     

Sonochemical and hydrodynamic cavitation reactors for laccase/hydrogen peroxide cotton bleaching

The main goal of this work is to develop a novel and environmental-friendly technology for cotton bleaching with reduced processing costs. This work exploits a combined laccase–hydrogen peroxide process assisted by ultrasound. For this purpose, specific reactors were studied, namely ultrasonic power generator type K8 (850 kHz) and ultrasonic bath equipment Ultrasonic cleaner USC600TH (45 kHz). The optimal operating conditions for bleaching were chosen considering the highest levels of hydroxyl radical production and the lowest energy input. The capacity to produce hydroxyl radicals by hydrodynamic cavitation was also assessed in two homogenizers, EmulsiFlex®-C3 and APV-2000. Laccase nanoemulsions were produced by high pressure homogenization using BSA (bovine serum albumin) as emulsifier. The bleaching efficiency of these formulations was tested and the results showed higher whiteness values when compared to free laccase. The combination of laccase–hydrogen peroxide process with ultrasound energy produced higher whiteness levels than those obtained by conventional methods. The amount of hydrogen peroxide was reduced 50% as well as the energy consumption in terms of temperature (reduction of 40 °C) and operating time (reduction of 90 min).     

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.     

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.