Application Of Ultrasonic Vibration Research Articles

Effect of Ultrasonic Treatment on Ti/Al Composite using Squeeze Casting: Microstructural Analysis and Mechanical Properties

To segregate the Titanium (Ti) from the reinforcements of the molten scrap of Titanium/Aluminum (Ti/Al) composite, application of ultrasonic vibration is known to be one of the sound techniques. Various studies have been looked at the effect of ultrasonic vibration on the melting process, however not much have been investigated with respect to the solidification process. To fabricate Ti/Al composites in situ, ultrasonic vibration can be effectively used to compress the solidifying melt during the casting process. In this line, the present study focused to investigate the influence of ultrasonic vibration and squeeze pressure on solidification behavior of the α-Al matrix, characteristics of the matrix-reinforcements interface, and distribution of reinforcements. The experimental data indicated that when the amplitude was 60 μm, the Vickers hardness, yield strength, and tensile strength of composites increased by 8.6, 3.9, and 3.1 %, respectively, due to gravity casting. While the squeeze pressure was increased from 50 to 100 MPa, the mean grain size decreased from 90 to 60 μm during the ultrasonic aided squeeze casting (SC) process. However, as the squeeze pressure was raised, the microstructures became coarser and the mechanical characteristics weakened. Yield strength, and tensile strength were increased by 18.7% and 3.2%, respectively, when the squeeze pressure was 100 MPa.

Application of ultrasonic vibration in magnesium alloy lap welding

In order to enhance the performance of magnesium alloy and galvanized steel welds, ultrasonic vibration was applied to the laser welding process, and the effect of ultrasonic on mechanical properties was verified through experimental methods. The laser welding system for the lap weld seam was designed, and the ultrasonic vibration module and image detection module were added, which can obtain the influence of ultrasonic vibration on the molten pool area. Under the conditions of ultrasonic vibration power of 1000 W and 0 W, the characteristics of the weld pool area, metallographic structure, tensile strength, fracture morphology, hardness, residual stress, wear resistance, and corrosion resistance of the weld specimen were compared. The image data acquisition structure indicated that ultrasonic vibration can effectively reduce the ineffective area of the molten pool and make the energy in the molten pool more concentrated. Under the influence of ultrasonic vibration, the maximum molten pool area decreased to 5.38 mm2, with a variation range of 3.9 %, and the proportion of pores was greatly reduced. Research found that ultrasonic vibration can significantly improve the microstructure characteristics of the fusion welding zone, with an average grain size reduced to 23 μm. The reduction of grain size and refinement of microstructure were beneficial to the improvement of mechanical properties of magnesium alloy joints, with a yield strength increase of 6.5 %. Ultrasonic vibration had little effect on the hardness of the heat affected zone, it can increase the average hardness of the weld zone by more than 5 % and reduce the maximum residual stress by more than 50 %. Under different pressure and friction speed conditions, the maximum wear amount can be reduced by more than 25 %. At the same time, the resistance to oxidation corrosion and electrochemical corrosion also can be improved to a certain extent.

Three-Dimensional Finite Element Modeling of Ultrasonic Vibration-Assisted Milling of the Nomex Honeycomb Structure

Machining of Nomex honeycomb composite (NHC) structures is of critical importance in manufacturing parts to the specifications required in the aerospace industry. However, the special characteristics of the Nomex honeycomb structure, including its composite nature and complex geometry, require a specific machining approach to avoid cutting defects and ensure optimal surface quality. To overcome this problem, this research suggests the adoption of RUM technology, which involves the application of ultrasonic vibrations following the axis of revolution of the UCK cutting tool. To achieve this objective, a three-dimensional finite element numerical model of Nomex honeycomb structure machining is developed with the Abaqus/Explicit software, 2017 version. Based on this model, this research examines the impact of vibration amplitude on the machinability of this kind of structure, including cutting force components, stress and strain distribution, and surface quality as well as the size of the chips. In conclusion, the results highlight that the use of ultrasonic vibrations results in an important reduction in the components of the cutting force by up to 42%, improves the quality of the surface, and decreases the size of the chips.

Enhancing the Machining Performance of Nomex Honeycomb Composites Using Rotary Ultrasonic Machining: A Finite Element Analysis Approach.

Nomex honeycomb composites (NHCs) are commonly used in various industrial sectors such as aerospace and automotive sectors due to their excellent material properties. However, when machining this type of structure, problems can arise due to significant cutting forces and unwanted cell vibrations. In order to remedy these shortcomings, this study proposes to integrate RUM (rotary ultrasonic machining) technology, which consists of applying ultrasonic vibrations along the axis of rotation of the cutter. To fully understand the milling process by ultrasonic vibrations of the NHC structure, a 3D numerical finite element model is developed using Abaqus/Explicit software. The results of the comparative analysis between the components of the simulated cutting forces and those from the experiment indicate a close agreement between the developed model and the experimental results. Based on the developed numerical model, this study comprehensively analyzes the influence of the ultrasonic vibration amplitude on various aspects, such as stress distribution in the cutting zone, chip size, the quality of the machined surface and the components of the cutting force. Ultimately, the results demonstrate that the application of ultrasonic vibrations leads to a reduction of up to 50% in the components of the cutting force, as well as an improvement in the quality of the machined surface and a reduction in the size of chips.

Analytical modeling of cutting force in vibration-assisted helical milling of Al 7075 alloy

Vibration-assisted helical milling is considered a promising hole-making process in the aerospace industry. The prediction of cutting force magnitude and behavior is very important to determine the cutting power, produce tight tolerance, eliminate tool wear, and improve the hole quality. Therefore, the main goal of this work is to establish a cutting force model and evaluate the cutting force coefficients, based on a mechanistic approach, during vibration-assisted helical milling of aerospace aluminum alloy (Al 7075). The process kinematics, the chip geometry including the chip width and chip thickness variations, and the tool-workpiece engagement are theoretically analyzed throughout the whole machining time. A set of experimental tests is implemented at different conditions of tangential feed and helical pitch. Additionally, model validation is performed to discuss the quality and accuracy of the presented model. Consequently, the behavior of the cutting force components against the application of ultrasonic vibration at different cutting conditions is demonstrated. The results show that the analytical and the experimental results are well agreed with a relatively small error percentage. The cutting force components generally increase as tangential feed and helical pitch increase. Moreover, the superimposed ultrasonic vibration causes a rapid tool-workpiece separation increasing the analytical and the experimental oscillation of the cutting force components, thus decreasing the average calculated cutting force.

Investigation of the effect of ultrasonic vibration on the performance of the friction drilling by FEM simulation

The friction drilling process is very important in various industries such as automotive, aerospace, and oil and gas industries. Therefore, they have always sought to find methods to improve this process. One of these methods is to optimize the application of ultrasonic vibrations in the process, and limited research has been done in this regard. The current research aims to investigate the effect of ultrasonic vibrations simultaneously with the parameters of drilling on the friction drilling process to optimize this process with the help of finite element simulation. Due to the nature of the complex transformations of the process, a Coupled Eulerian–Lagrangian model of the process was first created in the Abaqus software. Then, the process simulation was carried out in the presence and absence of ultrasonic vibrations. Rotational speed, feed rate, and amplitude of vibrations are the influencing parameters, and sheet temperature and axial force, and torque applied to the tool are the parameters investigated in this research. The results show that higher rotation speed and lower feed rate lead to a reduction of axial force and torque. Also, the application of ultrasonic vibration reduces up to 50.48% the axial force and up to 46.67% torque, and this reduction is improved by increasing the range of vibrations. The optimal mode was selected After analyzing 12 different modes based on the lowest amount of axial force and torque on the pin. It was found that the ideal mode occurs at a feed rate of 4.23 m/s and a rotation speed of 3000 rpm, with a 20-µm range. These findings and optimizing drilling parameters bring new horizons in material bonding techniques in various industries.

Evaluation of the influence of ultrasonic vibration on physical, tensile, and morphological properties of fused deposition modeled specimens

The use of fused deposition modeling (FDM) in printing polymers for various applications has been ever increasing. However, its utilization in printing polymers for high-strength and superior surface finish applications is still a challenge, primarily due to process intrinsic defects, i.e., voids between the layers and the rough exterior arising from unrestrained deposition of molten polymer. This research hypothesizes that application of ultrasonic vibration (USV) post-fabrication could minimize these shortcomings. For this investigation, ASTM D638 Type IV samples were FDM-printed using poly(lactic) acid (PLA). Through screening experiments, an optimized set of ultrasonic parameters was determined. Then, the effect of both-sided ultrasonic application was characterized. Subsequently, the impact of USV on the samples’ physical, tensile, and morphological properties was examined by varying the layer height, infill patterns, and % infill density. Up to 70% roughness reduction was observed as a result of post-FDM ultrasonic application. Additionally, the tensile strength of the samples increased by up to 15.31%. Moreover, for some lower % infill samples, post-ultrasonic tensile strengths were higher than 100% infill control samples. Analysis of scanning electron microscopy (SEM) and X-ray computed tomography (CT) imagery indicated enhanced layer consolidation and reduced void presence in samples treated with ultrasonic. The combination of ultrasonic-generated heat and downward pressure promoted a synergistic squeeze flow and intermolecular diffusion across consecutive layers of polymers. As a result, increased tensile strength and surface finish were achieved while dimensional change was marginal.

Effect of ultrasonic vibration on microstructural evolution, clad defects, and surface properties in laser direct energy deposition of Inconel 625

Laser direct energy deposition (DED) has some accompanying issues, such as existence of micropores, elemental segregation at grain boundaries, intergranular corrosion, etc. Therefore, the current work aims for a reduction in clad defects and enhancement in surface properties for laser direct deposition of Inconel 625 by implementing ultrasonic vibration. The acoustic streaming and cavitation effect induced by ultrasonic vibration results in the breaking of columnar grains, along with grain refinement and better elemental distribution in the matrix during the solidification process. The investigation is carried out for deposition using a 240 W Yb-fiber laser under the application of ultrasonic vibration with a variable amplitude of 6–13 μm (frequency: 33–28 kHz). A relatively higher vibration amplitude was found more efficient in converting long columnar grains into finer and uniformly distributed equiaxed grains, with a significant reduction in micropores. Further, it resulted in a shorter molten pool lifetime because of the generation of more nucleation centers, leading to better cooling. The above effects resulted in higher microhardness of the deposited layer. Further, the wear and corrosion resistance showed an improvement with the application of vibration, which may be due to the finer equiaxed grains, less porosity, and better elemental distribution at a higher vibration amplitude.

Enhancing the Deposition Rate and Uniformity in 3D Gold Microelectrode Arrays via Ultrasonic-Enhanced Template-Assisted Electrodeposition.

In the pursuit of refining the fabrication of three-dimensional (3D) microelectrode arrays (MEAs), this study investigates the application of ultrasonic vibrations in template-assisted electrodeposition. This was driven by the need to overcome limitations in the deposition rate and the height uniformity of microstructures developed using conventional electrodeposition methods, particularly in the field of in vitro electrophysiological investigations. This study employs a template-assisted electrodeposition approach coupled with ultrasonic vibrations to enhance the deposition process. The method involves utilizing a polymeric hard mask to define the shape of electrodeposited microstructures (i.e., micro-pillars). The results show that the integration of ultrasonic vibrations significantly increases the deposition rate by up to 5 times and substantially improves the uniformity in 3D MEAs. The key conclusion drawn is that ultrasonic-enhanced template-assisted electrodeposition emerges as a powerful technique and enables the development of 3D MEAs at a higher rate and with a superior uniformity. This advancement holds promising implications for the precision of selective electrodeposition applications and signifies a significant stride in developing micro- and nanofabrication methodologies for biomedical applications.

Enhancement mechanism of ultrasonic vibration on interface bonding strength in laser joining of polymer to ceramic

The current challenge in laser joining polymer and ceramic heterogeneous structures lies in their relatively low mechanical strength, primarily attributed to weak interface bonding. To address this issue, this paper proposes the application of ultrasonic vibration during the laser joining process of PET with both Si3N4 and Ti-coated Si3N4 sheets to enhance the interface bonding strength. Investigating the mechanisms underlying the enhancement of interface bonding strength due to ultrasonic vibration is crucial for improving the overall mechanical strength of the joints. It is found that the physical wetting thermodynamic conditions and chemical bond thermodynamic conditions for laser joining of PET to ceramics were the surface tension of ceramics higher than that of the molten PET and the variation in the Gibbs function less than −24.3 kcal/mol, respectively. Experimental results demonstrated that the bonding interface between Si3N4 sheet and PET exhibits only physical and mechanical bonding, with no evidence of new chemical bonds. However, XPS analysis detected new TiC bonds at the bonding interface of Ti-coated Si3N4 and PET. Furthermore, experimental results substantiated that ultrasonic vibration could improve the spreading wetting of PET melt on the Si3N4 surface, resulting in a 17 % increase in the bonded area of the weld seam. Additionally, ultrasonic vibration enhanced the molten PET filling into the blind hole structure on the Si3N4 surface, resulting in an approximately 73 % increase in the filling depth of the blind holes. Lastly, ultrasonic vibration facilitated the chemical reaction between the molten PET and Ti atoms, resulting in an approximately 57 % increase in the thickness of the interface containing TiC bonds. It is evident that ultrasonic vibration can bolster the interfacial bonding strength of PET/Si3N4 and PET/Ti-coated Si3N4 in laser joining. Moreover, in comparison to physical bonding, its more pronounced impact on mechanical and chemical bonding is noteworthy.

Burr constitution analysis in ultrasonic-assisted drilling of CFRP/nano-graphene via experimental and data-driven methodologies

In this study, a comprehensive investigation was undertaken to analyze the impact of various factors on thrust force and burr damage in carbon fiber reinforced polymer laminates during drilling operations. The factors examined included the incorporation of nano-graphene, the application of ultrasonic vibration, the type of cutting tool, and the feed rate. Statistical and machine learning techniques were employed to analyze the data, and image processing was utilized to illustrate the extent of burr damage surrounding the drilled holes. The developed model exhibited satisfactory prediction accuracy with minimal error rates. Statistical analysis revealed that the feed rate exerted the greatest influence on thrust force and facilitated the burr generation. Likewise, the addition of nano-graphene resulted in an increased thrust force due to improved rupture limits, consequently leading to cleaner holes with minimal burr damage. Furthermore, the implementation of ultrasonic vibration and the use of high-cobalt cutting tools were found to enhance drilling performance by reducing thrust force and minimizing the burr formation. The best hole quality was achieved at the lowest feed rate, in combination with a cutting tool containing 8% cobalt and the utilization of ultrasonic vibration.

Effect of Ultrasonic Vibration on Tensile Mechanical Properties of Mg-Zn-Y Alloy

Ultrasonic vibration assisted (UVA) plastic forming technology has proven to be a highly effective processing method, particularly for materials that are challenging to deform. In this research, UVA tensile tests were carried out on Mg98.5Zn0.5Y1 alloy at different vibration frequencies and amplitudes. The experimental results indicate that, compared with conventional tensile tests, the yield strength and tensile strength of Mg98.5Zn0.5Y1 alloy exhibit a decrease. Furthermore, the application of ultrasonic vibration demonstrates an ability to enhance the material’s elongation and plasticity. In order to further predict the stress-strain relationship in the metal tensile process, a hybrid constitutive model coupling the frequency and amplitude of ultrasonic vibration was developed based on the modified Johnson Cook model. The calculated results of the constitutive equation are in good agreement with the experimental results, indicating that the established constitutive equation can accurately predict the trend of alloy stress change at different amplitudes and frequencies. It establishes a theoretical foundation for scrutinizing the deformation mechanisms of the alloy under ultrasonic vibration. Furthermore, Abaqus finite element analysis software was employed to simulate and analyze the UVA tensile process, elucidating the impact of ultrasonic vibration on stress distribution, strain patterns, and material flow in the tensile behavior of Mg98.5Zn0.5Y1 alloys.

Comparative Study of Surface Integrity for AZ31B Magnesium Alloy during the Application of Ultrasonic Vibration and Laser Energies in the Turning Process

Comparative Study of Surface Integrity for AZ31B Magnesium Alloy during the Application of Ultrasonic Vibration and Laser Energies in the Turning Process

A way to limit the long-term degradation of solid oxide fuel cell cathode by decorating the surface with K2NiF4-Structure Pr4Ni3O10+δ phase

Prolonged annealing of La0.6Sr0.4Co0.2Fe0.8O3-δ (LSCF) at 700 °C for 1000 h resulted in phase segregation on the surface in the form of submicron-sized SrO on the grains and micron-sized CoFe2O4 particles near the grain boundaries during electrical conductivity relaxation (ECR) measurements. The presence of segregated particles results in a substantial decrease in the surface exchange coefficient, kchem. To mitigate this issue, the LSCF electrodes underwent a systematic coating process with the K2NiF4-structure Pr4Ni3O10+δ (PNO), while varying the loading content, thickness, and porosity. This is achieved by adjusting the gap between the nozzle exit and LSCF surface, ranging from 2 cm to 9 cm, coupled with the application of ultrasonic vibration of the nozzle chamber operating between 40 kHz and 180 kHz. Optimal surface coverage with a loading content of 0.28 mg cm−2 referred to as PNO5 results in a significant increase in kchem by up to one and a half order of magnitude compared to bare LSCF. The PNO coating effectively suppresses phase segregation during prolonged exposure, resulting in a substantial decrease in degradation. The improved performance is attributed to the optimal surface coverage of coated particulates, which enhances the active sites for oxygen reduction reaction (ORR) and the triple phase boundary (TPB) area. These exceptional characteristics position PNO coated LSCF as a highly promising cathode option for low temperature solid oxide fuel cells (SOFCs).

Unveiling the role of K2NiF4-Structure Pr4Ni3O10+δ surface coverage in boosting oxygen permeation and suppressing membrane degradation

To probe the oxygen flux over an extended period of 1000 h, oxygen permeation measurements are performed at 700 °C for La0.6Sr0.4Co0.2Fe0.8O3-δ (LSCF) coated with K2NiF4-structure Pr4Ni3O10+δ (PNO) while varying surface coverage. The optimization of PNO surface coverage, thickness, and porosity over LSCF involves the application of ultrasonic vibration of the nozzle chamber within the range of 40 kHz to 180 kHz. This is coupled with the adjustment of the gap between the nozzle exit and substrate surface, ranging from 2 cm to 9 cm. The results indicate that the PNO coating facilitated an increase in oxygen permeation and hindered the formation of secondary phases on the surface, known to cause degradation over time. When compared to bare LSCF, a minimal increase of 8 % in oxygen permeation is observed for the coated sample with a PNO loading content of 7.21 µm, denoted as PNO1. Conversely, the most significant enhancement of 74 % is seen for the loading content of 5.06 µm, referred to as PNO5. The LSCF membrane experiences a degradation of oxygen flux by 11 % after prolonged operation, significantly surpassing the mere 2.1 % degradation observed for the best-performing PNO5 membrane. This improvement is achieved by suppressing the segregated phases of SrO and CoFe2O4 on the surface. The observed enhancement in oxygen flux is attributed to the optimal surface coverage of the PNO-coated particulate, which increases the number of active sites for the oxygen reduction reaction (ORR).

Study on the materials flow, microstructure and mechanical properties of ultrasonic vibration-assisted friction stir weld of 1500 MPa martensitic steel

In this study, friction stir welding (FSW) was conducted on 1500 MPa martensitic steel with a thickness of 2.3 mm at 500 rpm and 60 mm/min with and without the application of ultrasonic vibration. The utilization of pure nickel as a marker material could help to visualize the material flow behavior throughout the whole FSW process. In addition, the width change of the marker material was used to distinguish the welding stages. At the same time, the microstructure was also characterized to study the effect of ultrasonic vibration on the welding process. The conventional FSW (C-FSW) joint had tunnel defects due to poor material flow, while the ultrasonic vibration-assisted FSW (U-FSW) joint was defect-free. To study the microstructure and texture evolution during the process, a fully austenitized welding zone was reconstructed from martensite to prior austenite grain (PAG) based on the Kurdjumov-Sachs orientation relationship. The strain rate increased in U-FSW compared to that in C-FSW, resulting in a reduction of the PAG size and an alteration of its shear texture components from type-A to type-B. The uniaxial tensile tests showed that the ultimate tensile strength (UTS) of the stir zone (SZ) of U-FSW was significantly increased compared with that of C-FSW.

In situ observation of melt pool evolution in ultrasonic vibration-assisted directed energy deposition

The presence of defects, such as pores, in materials processed using additive manufacturing represents a challenge during the manufacturing of many engineering components. Recently, ultrasonic vibration-assisted (UV-A) directed energy deposition (DED) has been shown to reduce porosity, promote grain refinement, and enhance mechanical performance in metal components. Whereas it is evident that the formation of such microstructural features is affected by the melt pool behavior, the specific mechanisms by which ultrasonic vibration (UV) influences the melt pool remain elusive. In the present investigation, UV was applied in situ to DED of 316L stainless steel single tracks and bulk parts. For the first time, high-speed video imaging and thermal imaging were implemented in situ to quantitatively correlate the application of UV to melt pool evolution in DED. Extensive imaging data were coupled with in-depth microstructural characterization to develop a statistically robust dataset describing the observed phenomena. Our findings show that UV increases the melt pool peak temperature and dimensions, while improving the wettability of injected particles with the melt pool surface and reducing particle residence time. Near the substrate, we observe that UV results in a 92% decrease in porosity, and a 54% decrease in dendritic arm spacing. The effect of UV on the melt pool is caused by the combined mechanisms of acoustic cavitation, ultrasound absorption, and acoustic streaming. Through in situ imaging we demonstrate quantitatively that these phenomena, acting simultaneously, effectively diminish with increasing build height and size due to acoustic attenuation, consequently decreasing the positive effect of implementing UV-A DED. Thus, this research provides valuable insight into the value of in situ imaging, as well as the effects of UV on DED melt pool dynamics, the stochastic interactions between the melt pool and incoming powder particles, and the limitations of build geometry on the UV-A DED technique.

Study on adhesive-film bonded Al/CFRP joints strengthened by ultrasonic vibration

This study proposed a method of the adhesive-film bonded aluminum/CFRP (carbon fiber reinforced polymer composite) joints strengthened by ultrasonic vibration. An orthogonal experiment was performed to optimize ultrasonic vibration parameters, improving the bonded joints’ shear strength and stability by 29% and 33%, respectively. Static wedge tests were conducted to study the durability of the adhesive joints, showing a 63% improvement. The strengthening mechanism was analyzed in terms of microstructure and chemical bonding. With the application of ultrasonic vibration, bubbles at the bond interface burst and overflowed, reducing the weak bonding area. At the same time, the adhesive film was promoted to fill the irregular micro pits on the adherend surface, enhancing the mechanical anchoring effect between the adhesive and the adhered plate. The probability of a reaction between the cyano group in the adhesive film and the hydroxyl group on the aluminum plate’s surface was increased under the ultrasonic vibration. More carbonyl and Al-N chemical bonds were formed between the adhesive film and the aluminum plate, thus improving the bonding performance of aluminum/CFRP.

Effect of Ultrasonic Frequency on Structure and Corrosion Properties of Coating Formed on Magnesium Alloy via Plasma Electrolytic Oxidation.

This study explores the application of ultrasonic vibration during plasma electrolytic oxidation (PEO) to enhance the corrosion resistance of magnesium (Mg) alloy. To this end, three different ultrasonic frequencies of 0, 40, and 135 kHz were utilized during PEO. In the presence of ultrasonic waves, the formation of a uniform and dense oxide layer on Mg alloys is facilitated. This is achieved through plasma softening, acoustic streaming, and improved mass transport for successful deposition and continuous reforming of the oxide layer. The oxide layer exhibits superior protective properties against corrosive environments due to the increase in compactness. Increasing ultrasonic frequency from 40 to 135 kHz, however, suppresses the optimum growth of the oxide layer due to the occurrence of super-soft plasma swarms, which results in a low coating thickness. The integration of ultrasonic vibration with PEO presents a promising avenue for practical implementation in industries seeking to enhance the corrosion protection of Mg alloys, manipulating microstructures and composition.

Application of ultrasonic vibration to shape-casting based on resonance vibration analysis

Application of ultrasonic vibration to shape-casting based on resonance vibration analysis