Numerical modelling of ultrasonic waves in a bubbly Newtonian liquid using a high-order acoustic cavitation model

To address difficulties in treating large volumes of liquid metal with ultrasound, a fundamental study of acoustic cavitation in liquid aluminium, expressed in an experimentally validated numerical model, is presented in this paper. To improve the understanding of the cavitation process, a non-linear acoustic model is validated against reference water pressure measurements from acoustic waves produced by an immersed horn. A high-order method is used to discretize the wave equation in both space and time. These discretized equations are coupled to the Rayleigh-Plesset equation using two different time scales to couple the bubble and flow scales, resulting in a stable, fast, and reasonably accurate method for the prediction of acoustic pressures in cavitating liquids. This method is then applied to the context of treatment of liquid aluminium, where it predicts that the most intense cavitation activity is localised below the vibrating horn and estimates the acoustic decay below the sonotrode with reasonable qualitative agreement with experimental data.     

超声清洗过程环境压力对声空化效应的影响*

在不同深度条件下的水下构建物超声清洗中,声空化是重要的源动力之一。为探明水下环境压力对声空化的影响,本文基于数值计算的方法,通过对超声波作用下气泡动力学的研究,讨论了环境压力对空化泡溃灭时的气泡最大半径、释放能量以及溃灭功率等因素的影响。结果表明：空化泡最大半径与环境压力在一定范围内呈近似线性关系;随着环境压力增大,空化泡释放能量和溃灭功率均显著减小,且两者在变化趋势和变化幅度上几乎一致;当环境压力大于声压幅值时,空化泡的最大半径、内部压强、内部温度与释放能量均远低于空化发生在环境压力小于声压幅值时的情形。     

Numerical simulation and experimental validation of ultrasonic de-icing system for wind turbine blade

It is widely accepted that wind energy is clean and renewable. However, icing on the blade surfaces of wind turbines is a serious problem in cold regions, which greatly affects its performance. Therefore, it is important to prevent ice accumulation on the surface of wind turbine blade and remove it whenever necessary. In this paper, a new non-thermal method–ultrasonic de-icing for wind turbine blade is proposed. Firstly, baced on the theory of ultrasonic de-icing, the harmonic analysis of the structure of the composite plate-ice layered system is investigated using the finite element method. The simulation results showed that ultrasonic de-icing method is feasible for wind turbine blade de-icing purposes. Secondly, the de-icing experiment of wind turbine blades using piezoelectric actuators is carried out in the freezer at a temperature of −15 °C, results showed that the ice layer can be debonded from the surface of wind turbine blade by the commonly used piezoelectric transducers made by PZT-5. The optimal frequency of ultrasonic de-icing of wind turbine blade is also given; finally, the installation way of ultrasonic transducers on the inner surface of wind turbine blade is given.     

Physical field simulation of the ultrasonic radiation method: An investigation of the vessel,probe position and power

In this paper, the effects of ultrasonic probe position, vessel shape, and ultrasonic input power on the sound pressure distribution in the reactor were investigated by solving the Helmholtz equation using COMSOL Multiphysis^@ software. Three different types of glass containers were used in the study, which are beaker, Erlenmeyer flask, and round bottom flask. The maximum value of sound pressure in the three containers will gradually increase when the distance between the probe and the bottom of the container decreases. When the distance decreases, the area of the high acoustic pressure region in the round bottom flask does not change significantly, while the area of the high acoustic pressure region in the beaker and Erlenmeyer flask increases sharply, which means that the use of the round bottom flask can reduce the influence of the dead zone on the preparation of nanomaterials. In addition, the change in power increases the value of the peak negative acoustic pressure in the vessel, enhancing the response efficiency of ultrasonic cavitation.     

A computational simulation study on the acoustic pressure generated by a dental endosonic file: Effects of intensity,file shape and volume

One of the uses of ultrasound in dentistry is in the field of endodontics (i.e. root canal treatment) in order to enhance cleaning efficiency during the treatment. The acoustic pressures generated by the oscillation of files in narrow channels has been calculated using the COMSOL simulation package. Acoustic pressures in excess of the cavitation threshold can be generated and higher values were found in narrower channels. This parallels experimental observations of sonochemiluminescence. The effect of varying the channel width and length and the dimensions and shape of the file are reported. As well as explaining experimental observations, the work provides a basis for the further development and optimisation of the design of endosonic files.     

Flow acoustics modelling and implications for ultrasonic flow measurement based on the transit-time method

A comparison between three mathematical models frequently used in flow acoustics is presented and discussed with respect to ultrasonic flow-meter performance based on the transit-time method. The flow-meter spoolpiece geometry is assumed to be a cylindrical pipe. Semi-analytical calculations employing the Frobenius power series expansion method are shown for the cases of a constant-, linear-, parabolic-, and cubic-flow profiles although the Frobenius method presented can be applied to any smooth flow profile. It is shown that the so-called deviation of measurement, often used as a measure of the flow-meter accuracy, is strongly dependent on the acoustic mode excited and the flow profile. Furthermore, differences with respect to deviation of measurement results exist among the three mathematical models analyzed.     

Controlled Space Radiation concept for mesh-free semi-analytical technique to model wave fields in complex geometries

Numerical modelling of the ultrasonic wave propagation is important for Structural Heath Monitoring and System Prognosis problems. In order to develop intelligent and adaptive structures with embedded damage detector and classifier mechanisms, detailed understanding of scattered wave fields due to anomaly in the structure is inevitably required. A detailed understanding of the problem demands a good modelling of the wave propagation in the problem geometry in virtual form. Therefore, efficient analytical, semi-analytical or numerical modelling techniques are required. In recent years a semi-analytical mesh-free technique called Distributed Point Source Method (DPSM) is being used for modelling various ultrasonic, electrostatic and electromagnetic wave field problems. In the conventional DPSM approach point sources are placed along the transducer faces, problem boundaries and interfaces to model incident and scattered fields. Every point source emits energy in all directions uniformly. Source strengths of these 360° radiation sources are obtained by satisfying interface and boundary conditions of the problem. In conventional DPSM modelling approach it is assumed that the shadow zone does not require any special consideration. 360° Radiation point sources should be capable of properly modelling shadow zones because all boundary and interface conditions are satisfied. In this paper it is investigated how good this assumption is by introducing the ‘shadow zone’ concept at the point source level and comparing the results generated by the conventional DPSM and by this modified approach where the conventional 360° radiation point sources are replaced by the Controlled Space Radiation (CSR) sources.     

Comparison of frequency domain and time domain methods for the numerical simulation of contactless ultrasonic cavitation

The use of a top-mounted electromagnetic induction coil has been demonstrated as a contactless alternative to traditional ultrasonic treatment (UST) techniques that use an immersed mechanical sonotrode for the treatment of metals in the liquid state. This method offers similar benefits to existing UST approaches, including degassing, grain refinement, and dispersion of nanoparticles, while also preventing contact contamination due to erosion of the sonotrode. Contactless treatment potentially extends UST to high temperature or reactive melts. Generally, the method relies on acoustic resonance to reach pressure levels suitable for inertial cavitation and as a result the active cavitation volume tends to lie deep in the melt rather than in the small volume surrounding the immersed sonotrode probe. Consequently, (i) with suitable tuning of the coil supply frequency for resonance, the treatment volume can be made arbitrarily large, (ii) the problem of shielding and pressure wave attenuation suffered by the immersed sonotrode is avoided. However, relying on acoustic resonance presents problems: (i) the emergence of bubbles alters the speed of sound, resonance is momentarily lost, and cavitation becomes intermittent, (ii) as sound waves travel through and reflect on all the materials surrounding the melt, the sound characteristics of the crucible and supporting structures need to be carefully considered. The physics of cavitation coupled with this intermittent behaviour poses a challenge to sonotrode modelling orthodoxy, a problem we are trying to address in this publication. Two alternative approaches will be discussed, one of which is in the time domain and one in the frequency domain, which couple the solution of a bubble dynamics solver with that of an acoustics solver, to give an accurate prediction of the acoustic pressure generated by the induction coil. The time domain solver uses a novel algorithm to improve simulation time, by detecting an imminent bubble collapse and prescribing its subsequent behaviour, rather than directly solving a region that would normally require extremely small time steps. This way, it is shown to predict intermittent cavitation. The frequency domain solver for the first time couples the nonlinear Helmholtz model used for studying cavitation, with a background source term for the contribution of Lorentz forces. It predicts comparable RMS pressures to the time domain solver, but not the intermittent behaviour due to the underlying harmonic assumption. As further validation, the frequency domain method is also used to compare the generated acoustic pressure with that of traditional UST using a mechanical sonotrode.     

一种保证超声清洗机性能的换能器大功率测试方法

本文较详细地叙述了生产超声清洗机过程中，对换能器频率，频带宽度，阻抗等参数实施一种简单而实用的大功率测试法，据此进行筛选来提高超声清洗机的性能。     

Determination of acoustic impedances of multi matching layers for narrowband ultrasonic airborne transducers at frequencies <2.5 MHz - Application of a genetic algorithm

The effective ultrasonic energy radiation into the air of piezoelectric transducers requires using multilayer matching systems with accurately selected acoustic impedances and the thickness of particular layers. One major problem of ultrasonic transducers, radiating acoustic energy into air, is to find the proper acoustic impedances of one or more matching layers. This work aims at developing an original solution to the acoustic impedance mismatch between transducer and air. If the acoustic impedance defences between transducer and air be more, then finding best matching layer(s) is harder. Therefore we consider PZT (lead zirconate titanate piezo electric) transducer and air that has huge acoustic impedance deference. The vibration source energy (PZT), which is used to generate the incident wave, consumes a part of the mechanical energy and converts it to an electrical one in theoretical calculation. After calculating matching layers, we consider the energy source as layer to design a transducer. However, this part of the mechanical energy will be neglected during the mathematical work. This approximation is correct only if the transducer is open-circuit. Since the possibilities of choosing material with required acoustic impedance are limited (the counted values cannot always be realized and applied in practice) it is necessary to correct the differences between theoretical values and the possibilities of practical application of given acoustic impedances. Such a correction can be done by manipulating other parameters of matching layers (e.g. by changing their thickness). The efficiency of the energy transmission from the piezoceramic transducer through different layers with different thickness and different attenuation enabling a compensation of non-ideal real values by changing their thickness was computer analyzed (base on genetic algorithm). Firstly, three theoretical solutions were investigated. Namely, Chebyshev, Desilets and Souquet theories. However, the obtained acoustic impedances do not necessarily correspond to a nowadays available material. Consequently, the values of the acoustic impedances are switched to the nearest values in a large material database. The switched values of the acoustic impedances do not generally give efficient transmission coefficients. Therefore, we proposed, in a second step, the use of a genetic algorithm (GA) to select the best acoustic impedances for matching layers from the material database for a narrow band ultrasonic transducer that work at frequency below the 2.5 MHz by considering attenuation. However this bank is rich, the results get better. So the accuracy of the propose method increase by using a lot of materials with exact data for acoustic impedance and their attenuation, especially in high frequency. This yields highly more efficient transmission coefficient. In fact by using increasing number of layer we can increase our chance to find the best sets of materials with valuable both in acoustic impedance and low attenuation. Precisely, the transmission coefficient is almost equal to unity for the all studied cases. Finally the effect of thickness on transmission coefficient is investigated for different layers. The results showed that the transmission coefficient for air media is a function of thickness and sensitive to it even for small variation in thickness. In fact, the sensitivity increases when the differences of acoustic impedances to be high (difference between PZT and air).     

微泡对高强度聚焦超声声压场影响的仿真研究*

微泡对高强度聚焦超声(HIFU)治疗焦域具有增效作用,而HIFU治疗中不同声学条件下微泡对HIFU形成声压场的影响尚不清楚。本文基于气液混合声波传播方程、Keller气泡运动方程、时域有限差分(FDTD)法和龙格-库塔(RK)法数值仿真研究输入声压、激励频率、气泡初始空隙率和气泡初始半径对HIFU形成声压场的影响。研究结果表明,随着输入声压的增大,焦点处声压升高但焦点处最大声压与输入声压的比值减小,焦点位置几乎不变;随着激励频率和气泡初始半径的增大,焦点处声压升高且焦点位置向远离换能器方向移动;随着气泡初始空隙率的增大,焦点处声压降低且焦点位置向换能器方向移动。     

New technology for the design of advanced ultrasonic transducers for high-power applications

A new high-frequency ultrasonic transducer for wire bonding has been conceived, designed, prototyped and tested. In the design phase an advanced approach was used and established. The method is based on the two basic principles of modularity and iteration. The transducer is decomposed to its elementary components. For each component an initial design is obtained with finite elements method (FEM) simulations. The simulated ultrasonic modules are then built and characterized experimentally through laser-interferometry measurements and electrical resonance spectra. The comparison of simulation results with experimental data allows the parameters of FEM models to be iteratively adjusted and optimized. The achieved FEM simulations exhibit a remarkably high-predictive potential and allow full control on the vibration behavior of the ultrasonic modules and of the whole transducer. The new transducer is fixed on the wire bonder with a flange whose special geometry was calculated by means of FEM simulations. This flange allows the converter to be attached on the wire bonder not only in longitudinal nodes but also in radial nodes of the ultrasonic field excited in the horn. This leads to a nearly complete decoupling of the transducer to the wire bonder, which has not been previously obtained. The new approach to mount ultrasonic transducers on a welding-device is of major importance not only for wire bonding but also for all high-power ultrasound applications and has been patented.     

Ultrasound-assisted soil washing processes for the remediation of heavy metals contaminated soils: The mechanism of the ultrasonic desorption

Ultrasound-assisted soil washing processes were investigated for the removal of heavy metals (Cu, Pb, and Zn) in real contaminated soils using HCl and EDTA. The ultrasound-assisted soil washing (US/Mixing) process was compared with the conventional soil washing (Mixing) process based on the mechanical mixing. High removal efficiency (44.8% for HCl and 43.2% for EDTA) for the metals was obtained for the most extreme conditions (HCl 1.0 M or EDTA 0.1 M and L:S = 10:1) in the Mixing process. With the aide of ultrasound, higher removal efficiency (57.9% for HCl and 50.0% for EDTA) was obtained in the same extreme conditions and similar or higher removal efficiency (e.g., 54.7% for HCl 0.5 M and L:S = 10:1 and 50.5% for EDTA 0.05 M and L:S = 5:1) was achieved even in less extreme conditions (lower HCl or EDTA concentration and L:S ratio). Therefore, it was revealed that the US/Mixing was advantageous over the conventional Mixing processes in terms of metal removal efficiency, consumption of chemicals, amount of generated washing leachate, and volume/size of washing reactor. In addition, the heavy metals removal was enhanced for the smaller soil particles in the US/Mixing process. It was due to more violent movement of smaller particles in slurry phase and more violent sonophysical effects. In order to understand the mechanism of ultrasonic desorption, the desorption test was conducted using the paint-coated beads with three sizes (1, 2, and 4 mm) for the free and attached conditions. It was found that no significant desorption/removal of paint from the beads was observed without the movement of beads in the water including floatation, collision, and scrubbing. Thus, it was suggested that the simultaneous application of the ultrasound and mechanical mixing could enhance the physical movement of the particles significantly and the very high removal/desorption could be attained.     

An erosion sensor based on a quartz crystal microbalance for quantitative determination of the cleaning efficiency in an ultrasonic vessel

The efficiency of ultrasonic cleaning vessels cannot be measured directly in an easy way. In the presented work, a sensor is developed which quantitatively measures the ablation of a test layer. The sensor element is a quartz crystal which is coated with a sacrificial layer. Small changes in mass of this layer can be measured by a frequency shift of the crystal oscillation. For measurements, a 10 MHz AT-cut quartz crystal was used in a cleaning vessel working at 44.9 kHz. To determine the frequency shift by the ablation of the test layer, the quartz crystal was driven by a frequency generator sweeping the frequency in the range of the resonance frequency and a characteristic frequency was determined. The test layer which was applied to the quartz crystal consisted of silica microparticles suspended in varnish. In a preliminary experiment using a commercial cleaner it could be shown that significant changes in resonance frequency by cavitation effect could be detected. The initial frequency shift of the sacrificial layer is reproducible within 10%. The test layer can be adapted to the conditions of the cleaning vessel. By changing the electrical input power of the vessel, a threshold in the cavitation erosion was found.     

On the problem of coupling of ultrasonic receivers to layered structures for process control

Different layers in the construction of ultrasonic receiving transducers have been identified as a significant factor in the frequency response of these transducers. The discussion has been extended to the reception of signals through the layers of a process vessel-wall to determine whether the resulting system can be made independent of frequency over a significant spectral range and whether a system can be identified that is essentially independent, in its spectral response, to the thickness of one of the layers (the couplant to the vessel). While the present results are limited to a frequency range of 0–2 MHz, they can readily be extended to other frequency ranges. These computations have as variables the backing material, the transducer material, a wear plate, one or two quarter wavelength layers, the couplant and the structure of the vessel wall. The effect of thin bonding layers for the quarter wavelength plates is also briefly considered. As may have been expected each extra layer introduced into the system produces its own series of resonances. The case of a number of quarter wavelength layers can give a flat frequency response over almost a megahertz of bandwidth but great care needs to be taken with the bonding layers. A system in which the thickness of the couplant had little effect on the overall spectral response was not found.     

A new technique for the identification of ultrasonic flaw signals using deconvolution

The identification of ultrasonic flaw signals is a difficult task in the angle beam ultrasonic testing of welded joints due to the presence of non-relevant signals from the geometric reflectors such as weld-roots and counter-bores. This paper describes a new approach to identify ultrasonic flaw signals in such a problematic situation. A similarity function is defined as the deconvolution of a target signal by a reference signal. The similarity functions for the same type of flaws/references are symmetric bandlimited impulse-like patterns with larger amplitudes while those for different types of flaws/references are asymmetrical broad patterns with relatively smaller amplitudes. Therefore, ultrasonic signals could be identified by the pattern of the similarity function. In the initial experiments, the proposed technique showed great potential for identifying ultrasonic flaw signals in the inspection of weld joints.     

On the validity and improvement of the ultrasonic pulse-echo immersion technique to measure real attenuation

A fundamental assumption embraced in conventional use of the ultrasonic pulse-echo immersion technique to measure attenuation in solid materials is revisited. The cited assumption relies on perfect and immutable adhesion at the water to sample interface, a necessary condition that allows calculating the reflection coefficient at any interface from elastic wave propagation theory. This parameter is then used to correct the measured signal and obtain the real attenuation coefficient of the sample under scrutiny. In this paper, cases in which the perfectly cohesive interfacial condition is not satisfied are presented. It is shown also that in those cases, the repeatability of the conditions at the interface is always uncertain. This implies that the reflection coefficients are unknown, even when density is known. A new method of simultaneously measuring the reflection coefficients for both exposed interfaces that are normal to the transducer, and the attenuation coefficient of the specimen is developed and is presented here. The robustness of the new method is proven, as we demonstrate that the proper value of attenuation is achieved independently of the continuously varying interfacial conditions of these non-ideal cases.     

Studies of a novel sensor for assessing the spatial distribution of cavitation activity within ultrasonic cleaning vessels

This paper describes investigations of the spatial distribution of cavitation activity generated within an ultrasonic cleaning vessel, undertaken using a novel cavitation sensor concept. The new sensor monitors high frequency acoustic emissions (>1 MHz) generated by micron-sized bubbles driven into acoustic cavitation by the applied acoustic field. Novel design features of the sensor, including its hollow, cylindrical shape, provide the sensor with spatial resolution, enabling it to associate the megahertz acoustic emissions produced by the cavitating bubbles with specific regions of space within the vessel. The performance of the new sensor has been tested using a 40 kHz ultrasonic cleaner employing four transducers and operating at a nominal electrical power of 140 W under controlled conditions. The results demonstrate the ability of the sensors to identify 'hot-spots' and 'cold-spots' in cavitation activity within the vessel, and show good qualitative agreement with an assessment of the spatial distribution of cavitation determined through erosion monitoring of thin sheets of aluminium foil. The implications of the studies for the development of reliable methods of quantifying the performance of cleaning vessels are discussed in detail.