Ultrasonic Process Research Articles

Processing parameter effect, formation mechanism and inhibition method of micro-hole exit defects in rotary ultrasonic pecking drilling of SiCf/SiC composites

High brittleness and anisotropy of ceramic matrix composites lead to great challenges for micro-hole machining. Micro-holes with large depth-to-diameter ratio (10:1) of SiCf/SiC composites were machined by rotary ultrasonic pecking drilling process. Based on the mechanical theory and structural characteristics of SiCf/SiC, a critical thrust force model was established. The effects of processing parameters on machining accuracy and machining quality of micro-hole exits were analyzed and parameters were optimized. The formation mechanism of exit defects includes interfacial debonding, fiber bending and matrix fracture. A method based on the surface morphology to inhibit exit defects by increasing the support stiffness of the material was proposed, under which the exit roundness all reached IT8 level and chipping factors decreased by 53 %–67 %, and only a small amount of chipping and micro-cracks was at the exit. The proactive control of micro-hole exit defects was realized, and a better machining quality was obtained.

A biodegradable polymer stent with high radial performance: Potential for treatment of portal vein stenosis

AbstractBiodegradable polymer stents have a wide application prospect in the treatment of vascular stenosis diseases. However, weak radial performance of polymer stents hinders the treatment of the diseases with high demand for radial supporting, such as portal vein stenosis. According to previous research, the constraint mode between monofilaments is a key factor that affects the radial performance of polymer braided stent. In this work, a series of Poly(l‐lactic acid) (PLLA) stents with the elastomer coating were prepared by ultrasonic spraying process to realize the constraints of monofilament cross points. The results are showed that the radial stiffness and peak force of the coated stent are significantly increased, up to 28 and 35 times higher than that of the bare stent. It is found that the cross points are constrained by the coating, which improves the constraining force between the monofilaments resulting in the increase of the radial force during the deformation process. More importantly, the mechanism of action between the radial force of the coated stent and the mechanical performance of elastic coating has been proposed, revealing a significant positive correlation between them. The radial force of the coated stent could be quantitatively regulated by the six‐arm poly(l‐lactide‐co‐ε‐caprolactone) (6SPLCL) coating cross‐linked by Hexamethylene diisocyanate (HDI) in different proportions. Finally, we build a mechanical model of stents and find that there is a consistency between the theoretical curve and the actual curve trend. This provides further research and expands the application scope for improving the radial supporting performance of the biodegradable polymer stent.

Coupled thermomechanical finite element analysis of ultrasonic hot embossing process

Ultrasonic Hot Embossing of polymers is one of the most attractive manufacturing methods of high-quality and complex microparts needed for biological and chemical processes. A little simulation work has been done to study the deformation mechanism and the required load in the Ultrasonic Hot Embossing of polymethyl methacrylate (PMMA). This paper developed a 2D coupled thermo-mechanical finite element model to simulate the forming behavior of the ultrasonic embossing process of PMMA, optimize the mold microfeature corner, and predict the embossing load as well. VDISP ABAQUS subroutine has been used to describe the downward motion of the mold assisted with ultrasonic vibration. The Arbitrary Eulerian-Lagrangian re-meshing technique has been implemented to refine the deformation zone during simulation to avoid divergence due to localized excessive deformation. Embossing load, temperature, stresses, strains, and energy dissipation have been recorded and analyzed. Simulation results revealed that the coupled thermo-mechanical FE Model efficiently captures the deformation behavior and Embossing load. It also proved that a Mold microfeature corner of 20 μm filet radius is recommended to adequately fill out the area around the mold and maintain uniform temperature and strain distributions.

Theoretical Modeling and Surface Roughness Prediction of Microtextured Surfaces in Ultrasonic Vibration-Assisted Milling

Textured surfaces with certain micro/nano structures have been proven to possess some advanced functions, such as reducing friction, improving wear and increasing wettability. Accurate prediction of micro/nano surface textures is of great significance for the design, fabrication and application of functional textured surfaces. In this paper, based on the kinematic analysis of cutter teeth, the discretization of ultrasonic machining process, transformation method of coordinate systems and the cubic spline data interpolation, an integrated theoretical model was established to characterize the distribution and geometric features of micro textures on the surfaces machined by different types of ultrasonic vibration-assisted milling (UVAM). Based on the theoretical model, the effect of key process parameters (vibration directions, vibration dimensions, cutting parameters and vibration parameters) on tool trajectories and microtextured surface morphology in UVAM is investigated. Besides, the effect of phase difference on the elliptical shape in 2D/3D ultrasonic elliptical vibration-assisted milling (UEVAM) was analyzed. Compared to conventional numerical models, the method of the cubic spline data interpolation is applied to the simulation of microtextured surface morphology in UVAM, which is more suitable for characterizing the morphological features of microtextured surfaces than traditional methods due to the presence of numerous micro textures. The prediction of surface roughness indicates that the magnitude of ultrasonic amplitude in z-direction should be strictly limited in 1D rotary UVAM, 2D and 3D UEVAM due to the unfavorable effect of axial ultrasonic vibration on the surface quality. This study can provide theoretical guidance for the design and fabrication of microtextured surfaces in UVAM.

Effect of low-frequency ultrasound-assisted acid extraction on gel properties and structural characterization of sheep's hoof gelatin

In this study, we investigated the effects of various low-frequency ultrasound-assisted extraction processes, including ultrasound-assisted acid-soaked water bath extraction (UAW), ultrasound-assisted water bath extraction after acid soaking (AUW), acid-soaked water bath extraction followed by ultrasonics (AWU), and acid-soaked water bath extraction without ultrasound (CON), on the structural properties, thermal stability, gel properties, and microstructure of sheep's hoof gelatin. The results revealed that the primary components of sheep's hoof gelatin consisted of α1-chain, α2-chain (100–135 kDa), and β-chain. In addition, it was observed that among the three sonication groups, sheep's hoof gelatin extracted in the AUW group exhibited the highest yield (27.16 ± 0.41 %), the best gel strength (378.55 ± 7.34 g), and higher viscosity at the same shear rate. The gelling temperature (25.38 ± 0.45 °C) and melting temperature (32.28 ± 0.52 °C) of sheep's hoof gelatin in the AUW group were significantly higher than those in the other groups (p > 0.05). Moreover, our experiments revealed that the sequence of low-frequency ultrasonic pretreatment processes was a crucial factor influencing the gel properties and structural characteristics of sheep's hoof gelatin. Specifically, the acid treatment followed by the ultrasound-assisted approach in the AUW group yielded high-quality and high-yield sheep's hoof gelatin.

Synthesis and antimicrobial behaviour of NiO/Ag-based material

The main objective of the present work is the green synthesis of NiO and Ag nanoparticles using the leaf extract of Azadirachta indica and the development of NiO/Ag-based nanocomposites via an ultrasonic process. The synthesised NiO/Ag was characterised using different analytical methods and used as an antimicrobial agent against different bacterial and fungal strains. The antimicrobial study was done using the well diffusion method. The FTIR study indicated the presence of O–H, C–H (methylene or methyl), CO, O–H, and Ni–Ag, Ag–O, or Ni–O bonds on the surface of NiO/Ag. The XRD peaks of NiO/Ag were found to be 31.60 (103), 37.30 (111), 38.10 (111), 43.40 (200), 62.90 (220), 76.50 (008), 77.50 (311), and 79.50 (222), respectively. The maximum zones of inhibition were found to be 21.6 (±0.71), 21.2 (±0.69), 17.9 (±0.39), 13.3 (±0.81), and 12.3 (±0.38) mm against Escherichia coli, Staphylococcus aureus, Salmonella enterica, Candida albicans, and Aspergillus niger after incubation periods. On the basis of these findings, we can conclude that NiO/Ag is a potent antimicrobial agent against a variety of bacterial and fungal species.

Investigation of engine performance, exhaust emissions, and combustion characteristics of a diesel engine fueled with Adansonia digitata methyl ester doped with nanosilica additive extracted from agricultural waste

AbstractRecent studies have used nanoparticle additions to enhance the fuel properties of biodiesel. However, it is unclear how these additives would affect engine operation. The effects of commercial nanoadditives on engines have been the subject of several studies. The current study focuses on nanoparticles derived from agricultural waste – specifically rice husk (RH) – to enhance their value. This study therefore examined silica (SiO2) doped with Adansonia digitata methyl ester (ADME) and tested it in a diesel engine. All nanofuel blends were prepared using an ultrasonication process, incorporating 400 ppm of SiO2 nanoparticles, fuels, and 1% surfactants. The results revealed that the brake thermal efficiencies (BTE) at maximum brake power (BP), for B20, B20 + SiO2, B100, and B100 + SiO2 fuels, were 29.9%, 28.2%, 28.44%, and 27.1%, respectively. Brake‐specific fuel consumption (BSFC) was also reduced when the engine ran from 4 to 16 kW BP. The exhaust gas temperature (EGT) of B100 and B100 + SiO2 increased more than that of B20. The peak heat release rates (HRR) of the B100 + SiO2 and B20 + SiO2 were slightly higher by 2.9% and 2.6%, respectively than the neat B100 at medium BP. However, in‐cylinder gas pressure (CGP) increased in the following order: B20 + SiO2 < B20 < B100 < B100 + SiO2 < B0. Moreover, the exhaust emissions of nanofuel blends showed a greater reduction in CO, total hydrocarbon (THC), CO2, NOX, and particulate matter (PM) in comparison with B20 and B100. Overall, this study recommends that SiO2 nanoadditive is a beneficial substitute fuel additive to use with biodiesel and its blends due to enhanced engine performance efficiency and reduced emissions.

Reconstruction Mechanism of Surface Integrity for Laser Additive Manufactured 316 L Stainless Steel Subjected to Ultrasonic Surface Rolling Process: Numerical Simulation and Experimental Verification

Reconstruction Mechanism of Surface Integrity for Laser Additive Manufactured 316 L Stainless Steel Subjected to Ultrasonic Surface Rolling Process: Numerical Simulation and Experimental Verification

Recovery of carotenoids as bioactive compounds from peach pomace by an eco-friendly ultrasound-assisted enzymatic extraction

The industrial processing of fruits generates by-products. These by-products serve as a source of valuable bioactive compounds. In this study, carotenoid was extracted from peach pomace (PP) by using the ultrasound-assisted enzymatic extraction (UAEE), an eco-friendly method. The process conditions ensuring the highest carotenoid content and b* color value for UAEE were detected by response surface methodology (RSM). To demonstrate the effectiveness of the ultrasonic process, enzymatic extraction was carried out at the optimum point. Physicochemical (pH, titratable acidity, total soluble solids), color (L*, a*, b*, chroma value (ΔC) and color difference (ΔE), total phenolic compound (TPC) and antioxidant activity analyses (ABTS and FRAP) were carried. When the analysis results evaluated, the highest b* color parameter, TPC (761.10 mg gallic acid/L), ABTS (1933.33 mg Trolox/L) and FRAP (52.66 µmol Trolox/L) results of the extracts was observed with UAEE method. The study shows that ultrasound based upon the cavitation event was increased efficiency of enzymatic reaction with higher extraction yield and this provided in higher amounts of carotenoid and bioactive compounds. In other respects, when obtained carotenoid extracts are used in food formulations compatible with their acidic structure, they will contribute to protection of the product and minimizing color losses.

Synthesis of ultra-high molecular weight homo- and copolymers via an ultrasonic emulsion process with a fast rate

In the forefront of advanced materials, ultra-high molecular weight (UHMW) polymers, renowned for their outstanding mechanical properties, have found extensive applications across various domains. However, their production has encountered a significant challenge: the attainment of UHMW polymers with a low dispersity (Ɖ). Herein, we introduce the pioneering technique of ultrasound (US) initiated polymerization, which has garnered attention for its capability to successfully polymerize a multitude of monomers. This study showcases the synthesis of UHMW polymers with a comparatively low Ɖ ( ≤ 1.1) within a remarkably short duration ( ~ 15 min) through the amalgamation of emulsion polymerization and high-frequency ultrasound-initiated polymerization. Particularly noteworthy is the successful copolymerization of diverse monomers, surpassing the molecular weight and further narrowing the Ɖ compared to their respective homopolymers. Notably, this includes monomers like vinyl acetate, traditionally deemed unsuitable for controlled polymerization. The consistent production and uniform dispersion of radicals during ultrasonication have been identified as key factors facilitating the swift fabrication of UHMW polymers with exceptionally low Ɖ.

Surface integrity and rolling contact fatigue behavior of 18CrNiMo7-6 steel subjected to ultrasonic surface rolling process

In this study, the effect of ultrasonic surface rolling process (USRP) on the surface integrity and rolling contact fatigue (RCF) behavior of 18CrNiMo7-6 steel have been conducted. The different static loads and ultrasonic amplitudes on surface morphology, surface roughness, microstructure, microhardness, and residual stress were examined. Results revealed that USRP treatment resulted in a remarkably smooth surface with the surface roughness value Ra of 0.035 μm. Moreover, USRP treatment induced the formation of nanocrystalline and ultrafine crystalline structures on the surface layer. Additionally, the sample surface was subjected to a significant layer of residual compressive stress, reaching a maximum value of approximately −1243 MPa and extending to a depth of around 1500 μm. The surface microhardness had been increased to 808 HV0.2. The comprehensive integration of grain refinement, the increase of surface microhardness, and the induction of residual compressive stress led to an improvement in RCF life.

Investigation of hybrid ultrasonic machining process of Nomex honeycomb composite using a toothed disc cutter

Nomex honeycomb composite (NHC) has been increasingly used in the automotive, aerospace and defence applications due to its excellent thermal and mechanical properties. Its complex cellular hexagonal thin-walled configuration along with heterogeneous, soft and brittle nature pose substantial processing defects such as burr formation, tearing of walls, surface roughness, dimensional inaccuracy and low machining quality during conventional machining (CM). These surface defects have a substantial influence on the operating life and functional performance of its sandwiched structural members. Hybrid ultrasonic vibration assisted machining (HUSVAM) technology has been introduced to overcome such limitations. For an in depth research on HUSVAM of NHC using ultrasonic toothed disc cutter (UTDC), three dimensional finite element model was developed and experimental validation was carried out. The numerical simulation and experimental results were found to be in good agreement with one another. The influence of various machining parameters including the ultrasonic tool vibration amplitude (UTVA), feed rate (FR), depth of cut (DoC) and spindle angular speed (SAS) on NHC cutting forces, chip formation and surface quality was investigated using both HUSVAM and CM techniques. Furthermore, stresses, deformation and forces near tool-workpiece interaction along with the surface topography and morphologies were also analysed and compared for various operating conditions. A reduction in the cutting forces was found with the increase of SAS and UTVA (up to 65.47 % and 65.74 %, respectively). Although, the cutting forces were observed to increase by increasing the DoC and FR (up to 159.45 % and 126.33 %, respectively). DoC has a greater impact on the cutting forces among all machining parameters according to 4 levels, 4 factors (L16) orthogonal experiments based on Taguchi method. The results show that the chip formation and machining quality of NHC core can be improved with HUSVAM technique using UTDC. HUSVAM also reduced the cutting forces (up to 73 %) compared to CM. The ultrasonic toothed disc cutter generated large number of burr with very short length, no tearing defects and no uncut fibers as observed from scanning electron microscopy of NHC hexagonal cell structure, walls and triple points. A burr formation of less than 10 % was realized during HUSVAM of NHC cores for Fx≤3N, while it was found up to 20 % if Fx>3N, compared to at least 40 % during CM. The finite element model developed can be used to investigate the influence of HUSVAM on modern difficult to machine materials for enhanced surface quality.

Surface Properties and Fatigue Behavior of 6061 Aluminum Alloy by Multi-pass Ultrasonic Surface Rolling Process

Surface Properties and Fatigue Behavior of 6061 Aluminum Alloy by Multi-pass Ultrasonic Surface Rolling Process

One-pot extraction of nanocellulose from raw durian husk fiber using carboxylic acid-based deep eutectic solvent with in situ ultrasound assistance

Nanocellulose (CNF) has emerged as a promising alternative to synthetic petroleum-based polymers, but the conventional preparation process involves multiple tedious steps, heavily dependent on chemical input, and proves cost-inefficient. This study presented an, in situ ultrasound-assisted extraction using deep eutectic solvent (DES) based on choline chloride and oxalic acid for more facile production of CNF from raw durian husk fibers. FESEM analysis confirmed the successful extraction of web-like nanofibril structure with width size ranging from 18 to 26 nm. Chemical composition analysis and FTIR revealed the selective removal of lignin and hemicellulose from the raw fiber. As compared to post-ultrasound treatment, in situ ultrasound-assisted extraction consistently outperforms, yielding a higher CNF yield with finer fiber width and significantly reduced lignin content. Integrating this eco-friendly in situ ultrasonication-assisted one-pot extraction method with a 7.5 min interval yielded the highest CNF yield of 58.22 % with minimal lignin content. The superior delignification ability achieved through the proposed in situ ultrasound-assisted protocol surpasses the individual efficacy of DES and ultrasonication processes, neither of which yielded CNF in our experimental setup. This single-step fabrication process significantly reduces chemical usage and streamlines the production steps yielding web-structured CNF that is ideal for sustainable application in membrane and separator.

Tensile strength and immersion corrosion behavior of nano-ZnO, rare earth Gd reinforced Mg nanocomposites developed by novel stir ultrasonication process

This paper presents the tensile and immersion corrosion properties of Mg-Zn-0.2Gd-xZnO (x = 1, 1.5, 2 and 2.5 wt.%) alloy and nanocomposites developed by stir ultrasonication coupled with squeeze casting. The immersion corrosion tests were performed under the simulated body fluid (SBF) conditions. The microscopic measurements indicate that the examined alloys/nanocomposites exhibit a significant decrease in grain size when both alloying elements Gadolinium (Gd) and Zinc Oxide (ZnO) nanoparticles are added. The examination of the phase by XRD indicates the presence of α-Mg and Mg2Zn, Mg7Zn3 secondary phases, which act as barriers against corrosion. The study confirmed that the incorporation of nanoparticles ZnO content ranging from 1 to 2.5 wt. % leads to a notable enhancement in yield strength (140 to 230 MPa). From the immersion corrosion test, the nanocomposites with the inclusion of 2 wt. % ZnO ceramic nanoparticles resulted in the highest level of corrosion resistance with a corrosion rate of 0.049 mm per year. This nanocomposite also shows better wettability with improved hydrophilicity. The developed Mg based advanced nanocomposites have the potential to be used in load bearing implant applications as it exhibited high corrosion resistance characteristics.

Evolution of microstructure and mechanical properties of aluminum alloy induced by turning and ultrasonic surface rolling process

The microstructure and mechanical properties have a significant impact on the service performance of materials. This paper compared the microstructure and mechanical properties of 2024 aluminum alloy subjected to turning and ultrasonic surface rolling process (USRP). It was found that both turning and USRP can cause grain refinement and increased microhardness. The grain refinement induced by USRP was attributed to dislocation proliferation and T-phase fragmentation; At the same time, a quantitative relationship model between microhardness and microstructure during turning and USRP was constructed. The results showed that precipitation had the greatest impact on the microhardness induced by turning, while dislocations and grain refinement had the greatest impact on the microhardness induced by USRP; In addition, the mechanical performance response mechanism of the materials after turning and USRP was elucidated, and it was found that USRP can significantly enhance the yield strength of the materials.

Formation mechanism of surface gradient microstructure and mechanical properties evolution of Mg–Y-Nd-Gd-Zr alloy by ultrasonic rolling

The evolution mechanism of the microstructure and mechanical properties of a Mg–Y-Nd-Gd-Zr alloy subjected to different numbers of passes of the ultrasonic surface rolling process (USRP) was investigated. The results demonstrated an initial decrease followed by an increase in the surface roughness of the alloy. The optimal surface roughness was achieved after four passes, with a contour mean deviation of 0.06 μm and micro-roughness 10-point height of 0.55 μm. After the USRP, the alloy exhibited a composite gradient structure characterized by increased grain size and decreased dislocation, lamination, and twin densities. The depth of the gradient layer increased with each additional USRP pass, ranging from 650 μm (1 pass) to 910 μm (8 passes). Furthermore, the USRP treatment effectively enhanced the alloy strength; compared with the untreated samples; the yield strength increased by 34.2% in the gradient sample after one pass. No significant change was observed in the YS with an increasing number of rolling passes for Mg alloys, whereas both the tensile strength and elongation showed improvements. High-density twinning played a crucial role in enhancing the YS of the gradient samples without significant variation across different numbers of rolling passes, thus following a consistent pattern. The formation of more nanocrystals on the surface of Mg alloys after multiple rolling cycles is key to preventing premature fracture failure and improving the work-hardening rate.

Development of an acoustic doppler flow profiler and flow testing

The flow test with acoustic Doppler current profiler (ADCP) is a new flow test method developed and applied only in the last decade or so. However, because it involves many disciplines such as hydroacoustic physics, ultrasonic transducer technology, electronics, and signal processing, most of the ADCPs used at the present stage are imported, and the domestically produced high-precision ADCPs have a lot of space in the domestic market. This paper introduces the measurement principle of ADCP. Based on this principle, we have overcome the weak signal processing circuit and successfully developed a domestic horizontal fixed acoustic Doppler flow profiler. The instrument is used for flow tests in Yixing (South) Hydrological Station, and the results of the comparison and error analysis meet the requirements of the national first-class precision hydrological station in the “Hydrological Data Compilation Specification” to satisfy the needs of the daily test in the station. The “Horizontal Fixed Acoustic Doppler Profile Flow Rate System” was selected as one of the 100 typical cases of popularizing and applying the achievements of the Ministry of Water Resources in 2020, and it can replace the imported instruments.

Experimental study on surface roughness processed by ultrasonic surface rolling process

In order to explore the formation principle of microscopic morphology of the lower surface of USRP, USRP theoretical analysis and processing experiments are carried out. Firstly, the spatial motion trajectory of tool head by USRP is established to reveal formation principle of surface morphology. Additionally, this experiment employs a single-factor experimental design method. The influence law of process parameters and surface roughness is obtained. The results show that the workpiece speed affects the circumferential machining density of the part, and the feed speed affects the axial density of the part. Surface roughness initially decreases and subsequently increases with rising amplitudes and static pressure. It gradually rises with improvement of feed rate and rotational speed. This provides a new way to adjust the surface topography of USRP in the future.

Review on Ultrasonic Welding Quality Monitoring Technology

To produce batteries for electric vehicles, various welding processes are used, of which ultrasonic welding is an important one. In recent years, the quality control of welded components has become increasingly important due to fires and frequent discharges caused by battery heat. In addition, ultrasonic welding is sensitive to the process environment, so quality monitoring is essential. In this paper, we introduce a study to predict the quality of ultrasonic welding by measuring the energy generated during the welding process, the vibration of the horn and anvil, and the temperature of the weld. In particular, we will introduce various methods to measure the temperature of the weld, which is difficult to measure in the ultrasonic welding process, and a study that performs machine learning by fusing the energy and vibration obtained in the process.