Damage characteristics and surface description of near-wall materials subjected to ultrasonic cavitation

For the analysis of ultrasonic cavitation erosion on the surface of materials, the ultrasonic cavitation erosion experiments for AlCu4Mg1 and Ti6Al4V were carried out, and the changes of surface topography, surface roughness, and Vickers hardness were explored. Cavitation pits gradually expand and deepen with the increase of experiment time, and Ti6Al4V is more difficult to erode by cavitation than AlCu4Mg1. After experiments, the cavitation damage characteristics such as the single pit, the rainbow ring area, the fisheye pit, and some small pits were observed, which can be considered to be induced by a single micro-jet impact, ablation effect caused by the high temperature, micro-jet impingement with a sharp angle, and multibeam micro-jets coupling impact or negative pressure in the local area produced by micro-jet impact, respectively. The surface roughness and Vickers hardness of the material increase slowly after rapid growth at different points in time as the experiment time increases. With the increase of the ultrasonic amplitude, both of them first increase and then decrease after the ultrasonic amplitude is greater than 10.8 μm. The increases in surface roughness and Vickers hardness tend to decrease as the viscosity coefficient increases. Ultrasonic cavitation can cause submicron surface roughness and increase surface hardness by 20.36%, so it can be used as a surface treatment method.     

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.     

Numerical 3D flow simulation of ultrasonic horns with attached cavitation structures and assessment of flow aggressiveness and cavitation erosion sensitive wall zones

As a contribution to a better understanding of cavitation erosion mechanisms, a compressible inviscid finite volume flow solver with barotropic homogeneous liquid–vapor mixture cavitation model is applied to ultrasonic horn set-ups with and without stationary specimen, that exhibit attached cavitation at the horn tip. Void collapses and shock waves, which are closely related to cavitation erosion, are resolved. The computational results are compared to hydrophone, shadowgraphy and erosion test data. At the horn tip, vapor volume and topology, subharmonic oscillation frequency as well as the amplitude of propagating pressure waves are in good agreement with experimental data. For the evaluation of flow aggressiveness and the assessment of erosion sensitive wall zones, statistical analyses of wall loads and of the multiplicity of distinct collapses in wall-adjacent flow regions are applied to the horn tip and the stationary specimen. An a posteriori projection of load collectives, i.e. cumulative collapse rate vs. collapse pressure, onto a reference grid eliminates the grid dependency effectively for attached cavitation at the horn tip, whereas a significant grid dependency remains at the stationary specimen. The load collectives show an exponential decrease towards higher collapse pressures. Erosion sensitive wall zones are well predicted for both, horn tip and stationary specimen, and load profiles are in good qualitative agreement with measured topography profiles of eroded duplex stainless steel samples after long-term runs. For the considered amplitude and gap width according to ASTM G32-10 standard, the analysis of load collectives reveals that the distinctive erosive ring shape at the horn tip can be attributed to frequent breakdown and re-development of a small portion of the tip-attached cavity. This partial breakdown of the attached cavity repeats at each driving cycle and is associated with relatively moderate collapse peak pressures, whereas the stationary specimen is rather unfrequently stressed at the end of each subharmonic oscillation cycle by the violent collapse of the complete cavity.     

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

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

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

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

Effect of pearlitic morphology with varying fineness on the cavitation erosion behavior of eutectoid rail steel

The present work discusses the effect of the pearlitic morphology with varying fineness on the cavitation erosion behavior of eutectoid rail steel. Cavitation erosion of three different types of the pearlitic steels (furnace-cooled, air-cooled, and forced-air-cooled) consisting of coarse, fine, and very fine microstructures were tested in 3.5% NaCl solution and compared with that of the as-received pearlitic rail steel. The variation in the mean depth of erosion (MDE) and mean depth erosion rate (MDER) with erosion time was analyzed. Furthermore, the cavitation erosion resistance of the as-received, the air-cooled, and the forced-air-cooled was found to be 1.03, 1.51, and 2.14 times better than the furnace-cooled pearlitic steel, respectively. It was concluded that the cavitation erosion resistance of the pearlitic steel increased with the increase in the fineness of the microstructure.     

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.     

Computation of surface roughness using optical correlation

The laser speckle photography is used to calculate the average surface roughness from the autocorrelation function of the aluminum diffuse objects. The computed results of surface roughness obtained from the profile shapes of the autocorrelation function of the diffuser show good agreement with the results obtained by the stylus profile meter.      

Effect of surface lay in the surface roughness evaluation using machine vision

This work explores the influence of orientation of surface lay pattern of the machined components, while quantifying the surface roughness using machine vision approach. The surface images are captured from milled low carbon steel specimens with different roughness values using a vision system with coaxial lighting arrangement at different angular orientations of the work pieces (0°, 30°, 45°, 60°, 90°, 120°, 135°, 150°, and 180°). The captured images are subjected to preprocessing in order to retain the frequency components that attribute to roughness using a Gaussian filter by adapting the filtering procedures specified in ISO 4288. Numerous image based parameters such as gray level average (G_a), gray level co-occurrence matrix based image quantification parameters namely contrast, correlation, energy or uniformity, maximum probability and differential box courting based fractal dimension are computed from the surface images captured at different angular positions of the work piece. The computed vision based parameters are compared and correlated with the roughness average (R_a) obtained using a stylus instrument and the results are analyzed. The results clearly indicated that it is important to consider the orientation of the work piece when the machine vision approach is used to quantify the surface texture parameters.     

Geometric effects on surface roughness in precipitation

We investigate the branching of an advancing precipitation front to a nonplanar shape as the solute concentration in a supersaturated solution is increased beyond its critical value. We aim to learn whether new branches can be detected by measuring the speed of the front. We present a condition that determines whether a cross section of arbitrary shape will lead to a pitchfork or to a transcritical branching. Both are possible. Rectangles and circles imply pitchfork bifurcations, equilateral triangles and hexagons imply transcritical bifurcations.     

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

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

Quasistatic thermo-optical changes of acrylonitride-butadiene-styrene surface induced by laser beam

Surface quality of plastic material acrylonitride-butadiene-styrene (ABS) in a polycarbonate (PC) blend was investigated by probing samples obtained from industry using a HeNe laser beam. Peculiar optical behaviour such as a dynamic speckle pattern formation from rough, and temporal self-diffraction from smooth ABS/PC surfaces was observed. The reason for the peculiar behaviour was observed to result from the laser-induced thermal gradient, which was detected by using an IR imaging radiometer.     

Digital speckle interferometry for assessment of surface roughness

In this work, the principle of interferometry is used to assess the surface roughness of the machined surfaces. Interferometry produces an interference fringe pattern when two or more light waves interact with each other. It is one of the important tool for precision optical metrology and testing. Well-known advantages of the phase shifting interferometry include high measurement accuracy, rapid measurement, good result even with low contrast fringes and that the polarity of the wave front can be determined. In fringe projection techniques, a known optical fringe pattern is projected onto the surface of interest. The fringe pattern on the surface is perturbed in accordance with the profile of the test surface, thereby enabling direct derivation of surface profile.In this work, an attempt has been made to assess the surface roughness using a speckle fringe analysis method of five frame phase shift algorithm for machined surface (ground surface). As these fringes are too noisy, advanced filtering technique has been used so as to reduce noise and to get improved wrapped phase map from the phase shifted fringes. A phase unwrapping software has been developed using discrete cosine transform (DCT) to generate the three-dimensional (3-D) profiles. Finally, it is compared with R_a values measured using a mechanical stylus instrument, showing good agreement.     

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

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

Homogeneous model for surface roughness in identical double layer system

In this paper a homogeneous model for surface roughness in the identical double layer system has been presented. It has been shown that the reflectance change in non-absorbing layers is directly proportional to the square of the total thickness of the layers. In an absorbing layer, it has been shown that the thickness of each layer is equal to the surface roughness of the identical double layer system. The extinction coefficients of both layers are directly proportional to the thickness of that layer.     

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依据钨材料表面溅射的实验现象,建立钨材料表面粗糙模型,模拟了高能H+、He+粒子辐照下的钨材料表面的溅射行为过程,并与基于离子输运的双群模型计算得到的结果作了比较。结果表明,随着钨材料表面粗糙程度的增加,溅射率降低;对一定的粗糙表面,相同能量的不同入射粒子,质量越大粒子溅射率越高,这些结果为分析聚变装置中心等离子体杂质水平和评价偏滤器寿命等提供了一定的理论支撑。     

The effect of the high surface roughness in a comparative process

Comparative measurement methods are used to compare the behaviour of two macroscopically identical but microscopically different object surfaces. The roughness of these surfaces can have any value. The aim of this paper is to demonstrate theoretically as well as experimentally, the effect and the limitations of the high surface roughness on the visibility of the difference correlation fringes obtained in comparative processes.     

Influence of surface roughness on water- and oil-repellent surfaces coated with nanoparticles

Various rough surfaces coated with titanium oxide nanoparticles and perfluoroalkyl methacrylic copolymer were conducted to explore the influence of surface roughness on the performance of water- and oil-repellence. Surface characteristics determined from nitrogen physisorption at −196 °C showed that the surface area and pore volume increased significantly with the extent of nanoparticle ratio, indicating an increase of surface roughness. Due to the surface nano-coating, the maximum contact angles of water and ethylene glycol (EG) droplets increased up to 56 and 48%, respectively, e.g. from 105° to 164° for water droplets and from 96° to 144° for EG droplets. The excellent water- and oil-repellence of the prepared surfaces was ascribed to this increase of surface roughness and fluorinated-contained surface. Compared with Wenzel model, the Cassie model yielded a fairly good fit to the simulation of contact angle with surface roughness. However, a derivation of 3°–10° at higher roughness still existed. This phenomenon was very likely due to the surface heterogeneity with different pore size distributions of the fractal surfaces. In this case, it was unfavorable for super repellency from rough surface with larger mesopore fraction because of its capillary condensation, reflecting that micropore provided more air resistance against wettability.     

表面粗糙度对面向等离子体钨材料溅射的影响

依据钨材料表面溅射的实验现象,建立钨材料表面粗糙模型,模拟了高能H⁺、He⁺粒子辐照下的钨材料表面的溅射行为过程,并与基于离子输运的双群模型计算得到的结果作了比较。结果表明,随着钨材料表面粗糙程度的增加,溅射率降低;对一定的粗糙表面,相同能量的不同入射粒子,质量越大粒子溅射率越高,这些结果为分析聚变装置中心等离子体杂质水平和评价偏滤器寿命等提供了一定的理论支撑。