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.     

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.     

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.     

Interaction behaviors at the interface between liquid Al–Si and solid Ti–6Al–4V in ultrasonic-assisted brazing in air

Power ultrasonic vibration (20 kHz, 6 μm) was applied to assist the interaction between a liquid Al–Si alloy and solid Ti–6Al–4V substrate in air. The interaction behaviors, including breakage of the oxide film on the Ti–6Al–4V surface, chemical dissolution of solid Ti–6Al–4V, and interfacial chemical reactions, were investigated. Experimental results showed that numerous 2–20 μm diameter-sized pits formed on the Ti–6Al–4V surface. Propagation of ultrasonic waves in the liquid Al–Si alloy resulted in ultrasonic cavitation. When this cavitation occurred at or near the liquid/solid interface, many complex effects were generated at the small zones during the bubble implosion, including micro-jets, hot spots, and acoustic streaming. The breakage behavior of oxide films on the solid Ti–6Al–4V substrate, excessive chemical dissolution of solid Ti–6Al–4V into liquid Al–Si, abnormal interfacial chemical reactions at the interface, and phase transformation between the intermetallic compounds could be wholly ascribed to these ultrasonic effects. An effective bond between Al–Si and Ti–6Al–4V can be produced by ultrasonic-assisted brazing in air.     

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.     

Observations of cavitation erosion pit formation

Previous investigations showed that a single cavitation bubble collapse can cause more than one erosion pit (Philipp & Lauterborn [1]). But our preliminary study showed just the opposite – that in some cases a single cavitation pit can result from more than one cavitation event. The present study shows deeper investigation of this phenomenon. An investigation of the erosion effects of ultrasonic cavitation on a thin aluminum foil was made. In the study we observed the formation of individual pits by means of high speed cameras (>1000 fps) and quantitatively evaluated the series of images by stereoscopy and the shape from shading method. This enabled the reconstruction of the time evolution of the pit shape. Results show how the foil is deformed several times before a hole is finally punctured. It was determined that larger single pits result from several impacts of shock waves on the same area, which means that they are merely special cases of pit clusters (pit clusters where pits overlap perfectly). Finally it was shown that a thin foil, which is subjected to cavitation, behaves as a membrane. It was concluded that the physics behind erosion depends significantly on the means of generating cavitation (acoustic, hydrodynamic, laser light) and the specimen characteristics (thin foil, massive specimen), which makes comparison of results of materials resistance to cavitation from different experimental set-ups questionable.Further development of the shape from shading method in the scope of cavitation erosion testing will enable better evaluation of cavitation erosion models.     

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.     

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.     

超声滚压中的空化现象*

在超声滚压加工中引入切削液后可能会产生空化现象,由此产生的微射流和冲击波对超声表面强化将有积极作用。为研究超声滚压加工中空化现象是否存在及空化效应在超声滚压中的作用,本文首先分析了超声滚压中的空化阈值,然后进行了染色法试验和超声滚压后试样氧元素能谱分析,最后通过超声滚压加工对比试验研究了空化效应对加工后材料表面粗糙度和显微硬度的影响。研究发现,超声滚压加工中的声压幅值远大于空化阈值,满足空化存在的必要条件;超声滚压中发生了明显的卡纸染色现象,引入切削液后工件超声滚压加工表面氧元素含量显著提高,表明超声滚压中发生了空化现象。超声滚压加工中的空化效应能进一步降低工件表面粗糙度和提高表面显微硬度,有利于提高工件表面强化质量。本研究为空化效应在超声滚压中的积极利用提供了依据。     

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.     

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.     

An equivalent method of jet impact loading from collapsing near-wall acoustic bubbles: A preliminary study

Cavitation damage is a micro, high-speed, multi-phase complex phenomenon caused by the near-wall bubble group collapse. The current numerical simulation method of cavitation mainly focuses on the collapse impact of a single cavitation bubble. The large-scale simulation of the cavitation bubble group collapse is difficult to perform and has not been studied, to the best of our knowledge. In this study, the equivalent model of impact loading of acoustic bubble collapse micro-jets is proposed to study the cavitation erosion damage of materials. Based on the theory of the micro-jet and the water hammer effect of the liquid–solid impact, an equivalent model of impact loading of a single acoustic bubble collapse micro-jet is established under the principle of deformation equivalence. Since the acoustic bubbles can be considered uniformly distributed in a small enough area, an equivalent model of impact loading of multiple acoustic bubble collapse micro-jets in a micro-segment can be derived based on the equivalent results of impact loading of a single acoustic bubble collapse micro-jet. In fact, the equivalent methods of cavitation damage loading for single and multiple near-wall acoustic bubble collapse micro-jets are formed. The verification results show the law of cavitation deformation of concrete using equivalent loading is consistent with that of a micro-jet simulation, and the average relative errors and the mean square errors are insignificant. The equivalent method of impact loading proposed in this paper has high accuracy and can greatly improve the calculation efficiency, which provides technical support for numerical simulation of concrete cavitation.     

Quantitative evaluation of the microjet velocity and cavitation erosion on a copper plate produced by a spherical cavity focused transducer at the high hydrostatic pressure

Cavitation erosion at the high hydrostatic pressure causes the equipment to operate abnormally for the huge economic losses. Few methods can quantitatively evaluate the cavitation erosion intensity. In order to solve this problem, the cavitation erosion on a copper plate was carried out in a spherical cavity focused transducer system at the hydrostatic pressure of 3, 6, and 10 MPa. Meanwhile, the corresponding cavitation threshold, the initial bubble radius, and the microjet velocity in the ultrasonic field are theoretically analyzed to determine the dimension and velocity of microjet based on the following hypotheses: (1) the influence of the coalescence on the bubble collapse is ignored; (2) the dimension of the microjet is equal to the largest bubble size without the influence of gravity and buoyancy. Using the Westervelt equation for the nonlinear wave propagation and the Johnson-Cook material constitutive model for the high strain rate, a microjet impact model of the multi-bubble cavitation was constructed. In addition, through the analogy with the indentation test, an inversion model was proposed to calculate the microjet velocity and the cavitation erosion intensity. The microjet geometric model was constructed from the dimension and velocity of the microjet. The continuous microjet impact was proposed according to the equivalent impact momentum and solved by the finite element method. The relative errors of the pit depth are 4.02%, 3.34%, and 1.84% at the hydrostatic pressure of 3, 6, and 10 MPa, respectively, and the relative error in the evolution of pit morphology is 7.33% at 10 MPa, which verified the reliability of the proposed models. Experimental and simulation results show that the higher the hydrostatic pressure, the greater the pit depth, pit diameter, the pit-to-microjet diameter ratio, and the cavitation erosion intensity, but the smaller the pit diameter-to-depth ratio. The cavitation erosion intensity becomes significant with the ongoing ultrasonic exposure. In addition, a comparison of the cavitation pit morphology in the microjet pulsed and continuous impact modes shows that the continuous impact mode is effective without the elastic deformation caused by the residual stress. Using the cavitation pit morphology at the different hydrostatic pressures, the microjet velocity can be estimated successfully and accurately in a certain range, whose corresponding errors at the lower and upper limit are 5.98% and 0.11% at 3 MPa, 6.62% and 9.14% at 6 MPa, 6.54% and 5.42% at 10 MPa, respectively. Our proposed models are valid only when the cavitation pit diameter-to-depth ratio is close to 1. Altogether, the cavitation erosion induced by multi-bubble collapses in the focal region of a focused transducer could be evaluated both experimentally and numerically. Using the cavitation pit morphology and the inversion model, the microjet velocity in a certain range could be estimated successfully with satisfactory accuracy.     

Emulsification mechanism in an ultrasonic microreactor: Influence of surface roughness and ultrasound frequency

An ultrasonic microreactor with rough microchannels is presented in this study for oil-in-water (O/W) emulsion generation. Previous accounts have shown that surface pits or imperfections localize and enhance cavitation activity. In this study cavitation bubbles are localized on the rough microchannels of a borosilicate glass microreactor. The cavitation bubbles in the microchannel are primarily responsible for emulsification in the ultrasonic microreactor. We investigate the emulsification mechanism in the rough microchannels employing high-speed imaging to reveal the different emulsification modes influenced by the size and oscillation intensity of the cavitation bubbles. The effect of emulsification modes on the O/W emulsion droplet size distribution for different surface roughness and frequency is demonstrated. The positive effect of the frequency on minimizing the droplet size utilizing a reactor with large pits is presented. We also demonstrate microreactor systems for a successful generation of miniemulsions with high dispersed phase volume fractions up to 20%. The observed emulsification mechanism in the rough microchannel offers new insights into the utility and scale-up of ultrasonic microreactors for emulsification.     

TiAlN coatings synthesised using a dense plasma focus system and varied focus shots

TiAlN coatings were synthesised by a 2.3 kJ pulsed plasma focus system. The effect of focus shots on crystallography, microstructure, surface morphology, roughness and hardness was investigated. The coating's crystallography and microstructure were investigated using X-ray diffraction (XRD) characterisation. The XRD data showed that TiAlN coatings were crystallised in the cubic NaCl B1 structure with orientations in the (111), (200), (220) and (311) crystallographic planes. Texture coefficients showed a competition between (111) and (200) planes. The coatings surface morphology and thickness analyses were carried out using scanning electron microscopy (SEM). SEM micrographs showed dense and uniformly spread film with fine-grained morphology with hardly any pit, hole and crater. The surface roughness and hardness of TiAlN coatings were investigated by atomic force microscopy and Vickers microhardness tester. Grain size and roughness were found to decrease, whereas thickness and hardness were found to increase, with increasing focus shots.     

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.     

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.     

The role of passive potential in ultrasonic cavitation erosion of titanium in 1 M HCl solution

The influence of the applied passive potential on the ultrasonic cavitation erosion of Ti specimen in 1 M HCl solution was investigated by mass loss experiment, scanning electron microscopy (SEM), electrochemical impedance spectra (EIS) and Mott–Schottky plot. The results showed that Ti was in the passive state within the potential region from −0.3 V_SCE to 1.5 V_SCE under ultrasonic cavitation erosion. The applied passive potential can obviously decrease the mass loss of Ti caused by ultrasonic cavitation erosion in 1 M HCl solution. The resistance of the passive film increased, the flat band potential moved to positive direction, and the donor density of the passive film decreased with increasing the passive potential. Finally, a physical model was provided to explain the experimental results based on energy band and semi-conductive theories.     

Numerical study on the desorption processes of oil droplets inside oil-contaminated sand under cavitation micro-jets

The removal of the adsorbed oil droplet is critical to deoiling treatment of oil-bearing solid waste. Ultrasonic cavitation is regarded as an extremely useful method to assist the oil droplets desorption in the deoiling treatment. In this paper, the effects of cavitation micro-jets on the oil droplets desorption were studied. The adsorbed states of oil droplets in the oil-contaminated sand were investigated using a microscope. Three representative absorbed states of the oil droplets can be summarized as: (1) the individual oil droplet adsorbed on the particle surface (2) the clustered oil droplets adsorbed on the particle surface; (3) the oil droplet adsorbed in a gap between particles. The micro-jet generation during the bubble collapse near a rigid wall under different acoustic pressure amplitudes at an ultrasonic frequency of 20 kHz was investigated numerically. The desorption processes of the oil droplets at the three representative absorbed states under micro-jets were also simulated subsequently. The results showed that the acoustic pressure has a great influence on the velocity of micro-jet, and the initial diameter of cavitation bubbles is significant for the cross-sectional area of micro-jets. The wall jet caused by a micro-jet impacting on the solid wall is the most important factor for the removal of the absorbed oil droplets. The oil droplet is broken by the jet impinging, and then it breaks away from the solid wall due to the shear force generated by the wall jet. In addition to a higher sound pressure, the cavitation bubble at a larger initial diameter is more important for the desorption of the clustered oil droplets. Conversely, the micro-jet generated by the cavitation bubble at a smaller initial diameter (0.1 mm) is more appropriate for the desorption of the oil droplet in a narrow or sharp-angled gap.