Upscaling environment-friendly cavitation melt treatment (UltraMelt2)
Lead Research Organisation:
Brunel University London
Department Name: BCAST
Abstract
Abstracts are not currently available in GtR for all funded research. This is normally because the abstract was not required at the time of proposal submission, but may be because it included sensitive information such as personal details.
People |
ORCID iD |
| Dmitry Eskin (Principal Investigator) |
Publications
Chankitmunkong S
(2019)
Microstructure evolution in an Al-Si piston alloy under ultrasonic melt processing
in IOP Conference Series: Materials Science and Engineering
Chankitmunkong S
(2020)
Structure refinement, mechanical properties and feasibility of deformation of hypereutectic Al-Fe-Zr and Al-Ni-Zr alloys subjected to ultrasonic melt processing
in Materials Science and Engineering: A
Chankitmunkong S
(2022)
Light Metals 2022
Chankitmunkong S
(2019)
Structure Modification upon Ultrasonic Processing of an AA4032 Piston Alloy: Comparison of Permanent Mold and Direct-Chill Casting
in Metallurgical and Materials Transactions A
Dahlborg U
(2018)
Solidification Processing of Metallic Alloys Under External Fields
Eskin D
(2020)
Ultrasonic processing of aluminium alloys above the liquidus: the role of Zr
in MATEC Web of Conferences
Eskin DG
(2019)
Fundamental studies of ultrasonic melt processing.
in Ultrasonics sonochemistry
Khavari M
(2023)
Cavitation-induced shock wave behaviour in different liquids.
in Ultrasonics sonochemistry
| Description | A comprehensive numerical model for describing acoustic flows and cavitation have been improved. Experimental setups have been developed to study the interaction of melt flow with ultrasonic sources with the aim of optimising the residence time and efficiency of ultrasonic processing; as well as to provide data for computer stimulations. The role of shockwaves upon implosion of cavitation bubbles in fragmentation of intermetallics has been demonstrated by in-situ studies and analytical modelling. The unique experimental nanoindentation measurements allowed us to apply fracture mechanics to the analysis of fragmentation of intermetallics under cavitation. A number of mechanisms of ultrasonic emulsification were identified, and the role of gas in ultrasonic emulsification was revealed. A possibility of cavitation in highly-viscous melts was established and quantified. Pilot-scale trials have been performed upon direct-chill casting of Al alloys (with Constellium) and confirmed the possibility of ultrasonic processing in the melt flow (with optimised flow management), which was the main practical objective of the project. |
| Exploitation Route | The results so far allow us to apply the numerical modelling and simulation to optimising ultrasonic processing upon pilot-scale direct-chill casting of Al alloys. Pilot-scale trials have been successfully performed with the project partner Constellium. A grant application has been made to UKRI on the Manufacturing of Functional ImMiscible Alloys (FIMA), expanding and extending on the findings and expertise of UltraMelt2 project (same academic partners). |
| Sectors | Aerospace, Defence and Marine,Chemicals,Manufacturing, including Industrial Biotechology |
| Description | The numerical models developed in this project are the most sophisticated and complete to date and represent the state of the art. The application of these models to process simulation and optimisation is ongoing. The fundamental studies regarding the effects of cavitation, shock waves and acoustic streaming on the fragmentation of the phases, changes of the bulk flows and temperature fields are among most advanced in the field. Based on the developments in the project we have preformed pilot-scale trials with the industrial partner Constellium (UK) and confirmed the feasibility of the technological approach taken and applicability of the numerical models developed. There are ongoing talks about testing the optimised schemes of ultrasonic melt processing upon direct-chill casting at their facilities in France. A project proposal FIMA has been submitted to EPSRC in October 2021 expanding the scope of modelling and experimental work to metallic emulsions and contactless ultrasound. Despite very high grades it was not funded by EPSRC. Another project proposal PAAM on additive manufacturing has been funded and started in January 2023. The same team is now preparing a new research proposal HydrAl. |
| First Year Of Impact | 2022 |
| Sector | Aerospace, Defence and Marine,Energy,Manufacturing, including Industrial Biotechology,Transport |
| Impact Types | Economic |
| Description | Performance-driven design of aluminium alloys for additive manufacturing (PAAM) |
| Amount | £477,459 (GBP) |
| Funding ID | EP/W00593X/1 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 01/2023 |
| End | 01/2026 |
| Title | X-ray tomography scans of DC-cast billets (with and without UST) |
| Description | These image volumes (stacked .tif files) contain tomography scans that show the position of theromouples in the billet that is cast without ultrasonic treatment (no-UST) and in the billet that is cast with ultrasonic treatment (UST). |
| Type Of Material | Database/Collection of data |
| Year Produced | 2021 |
| Provided To Others? | Yes |
| URL | https://brunel.figshare.com/articles/dataset/X-ray_tomography_scans_of_DC-cast_billets_with_and_with... |
| Title | X-ray tomography scans of DC-cast billets (with and without UST) |
| Description | These image volumes (stacked .tif files) contain tomography scans that show the position of theromouples in the billet that is cast without ultrasonic treatment (no-UST) and in the billet that is cast with ultrasonic treatment (UST). |
| Type Of Material | Database/Collection of data |
| Year Produced | 2021 |
| Provided To Others? | Yes |
| URL | https://brunel.figshare.com/articles/dataset/X-ray_tomography_scans_of_DC-cast_billets_with_and_with... |
| Description | Calibration and data acquisition |
| Organisation | NPL Ltd |
| Country | United Kingdom |
| Sector | Private |
| PI Contribution | We provide datasets for the analysis. |
| Collaborator Contribution | NPL provides assistance in calibration of cavitometers as well as solving issues with data acquisition. This enhances their expertise in measuring acoustic parameters in liquid metals. |
| Impact | NPL used an advanced strategy/approach to calibrate our high-temperature cavitometer sensors in a range of frequencies (8-400 kHz) followed up with recommendations for a succesful implementation and recording of the data captured during liquid aluminium treatment. Their contribution was essential to this project as they managed to calibrate our sensors in the requested range of frequencies that was a very challenging exercise (especially in the low frequency spectrum (8 kHz). This calibration allowed us to publish a series of papers in the following journals: Ultrasonics Sonochemistry (2), Composites Part B: Engineering (1), Metals (1), Journal of Materials Research and Technology (1) as well 3 conference papers in the relevant proceedings. Also calibration of those sensors allowed us to monitor the pressure fields during experiments in a direct chill casting facility (Constelium) that aid the development of relevant numerical models and most importantly the facilitate optimisation of this industrial process. A conference paper is presented in TMS 2022 while a journal paper is expected. |
| Start Year | 2018 |
| Description | High temperature nanohardness |
| Organisation | Anton Paar |
| Department | Anton Paar Ltd |
| Country | United Kingdom |
| Sector | Private |
| PI Contribution | We provide large samples of intermetallics extracted from Al alloys (up to 1-2 mm) following an advanced strategy |
| Collaborator Contribution | Anton Paar measures nanohardness and extract mechanical properties at high temperatures, 600 to 700 C. |
| Impact | A technique to grow large intermetallic particles and extract them have been developed. The samples have been sent to Anton Paar (Switzerland). Data has been gathered for further analysis. Preliminary results are interesting. We expect a first of each kind journal paper based on the mechanical properties of intermetalics at elevated temperatures (up to 700 C) to be submitted/published in 2022. This will fill the gap in the existing knowledge on the behaviour of intermetalics at high temperatures, crucial for the development of high quality alloys. |
| Start Year | 2018 |
| Description | Single bubble cavitation |
| Organisation | University of Glasgow |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | Joint experiments have been performed on the effects of laser-induced single bubble cavitation on fragmentation of intermetallic crystals. We have provided materials, analysis and manpower. |
| Collaborator Contribution | Dr. P. Prentice kindly provided expertise and facilities for performing these experiments. |
| Impact | We expect to publish a number of papers based on the outcomes of this ongoing research. |
| Start Year | 2019 |
| Description | Ultra-high speed camera observations |
| Organisation | University of Glasgow |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | We have identify for the first time the prime responsible mechanism for the fragmentation of intermetalic crystals in a sonicated environment as well as the de-agglomeration and dispersion mechanisms of oxides in a sonicated liquid. |
| Collaborator Contribution | Allowed us to use their state of the art facility providing knowledge and expertise |
| Impact | Collaboration with Glasgow University led to the publications of 3 journal papers in the Journals of Fluid Mechanics (1) and Ultrasonics Sonochemistry (2) while another 2 conference papers have been included in the relevant proceedings. This was a fruitful collaboration with a decent number of outcomes that further advanced the existing knowledge on the field of shock waves as well as elucidate the mechanisms of bubble dynamics and their interaction with solid phases. |
| Start Year | 2019 |
| Description | Ultrasonic emulsification |
| Organisation | Northwestern Polytechnical University |
| Country | China |
| Sector | Academic/University |
| PI Contribution | BCAST (Brunel University London) and Oxford Brookes university have provided facilities and space for conducting experiments by a visiting PhD student. |
| Collaborator Contribution | A visiting PhD student (Webhua Wu) has conducted experiments, analysis of the data and written a journal paper. This work expanded the scope of the project towards ultrasonic emulsification with the potential to be used in the current grant proposal FIMA. |
| Impact | Wu WH, Eskin DG, Priyadarshi A, Subroto T, Tzanakis I, Zhai W. New insights into the mechanisms of ultrasonic emulsification in the oil-water system and the role of gas bubbles. Ultrason. Sonochem., 2021, vol. 73, p. 105501 doi.org/10.1016/j.ultsonch.2021.105501 |
| Start Year | 2019 |
| Description | Ultrasonic impregnation of composites |
| Organisation | German Aerospace Centre (DLR) |
| Department | DLR Braunschweig |
| Country | Germany |
| Sector | Public |
| PI Contribution | BCAST (Brunel University London) and Oxford Brookes University provided expertise and instruments for measuring cavitation upon ultrasonic impregnation of polymer-matrix composites. |
| Collaborator Contribution | DLR has provided expertise and facilities for ultrasonic impregnation of polymer-matrix composites. |
| Impact | Tzanakis I, Khavari M, Titze M, Eskin DG. Cavitation in Thermoplastic Melts: New Insights into Ultrasound-Assisted Fibre-Impregnation. Composites Part B: Engineering. 2022, vol 229, Paper 109480 (8 p.) doi.org/10.1016/j.compositesb.2021.109480 There is a potential to expand this collaboration to joint project proposal application, e.g. within Horizon Europe. |
| Start Year | 2020 |
| Description | Editing a Special Issue of Ultrasonics Sonochemistry |
| Form Of Engagement Activity | A magazine, newsletter or online publication |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Professional Practitioners |
| Results and Impact | A Special Issue on Sonoprocessing of Materials was launched from the Journal of Ultrasonics Sonochemistry (IF 7.491) with Guest Editors Professor Dmitry Eskin (Brunel London University, UK), Professor Iakovos Tzanakis (Oxford Brookes University, UK) and Professor Sergey Komarov (Tohoku University, Japan). Special issue expects to attract a large number of papers (>50) on a wide range of topics with a view to establishing links and collaborations between scientists with complementary interests. |
| Year(s) Of Engagement Activity | 2022 |
| URL | https://www.journals.elsevier.com/ultrasonics-sonochemistry/call-for-papers/call-for-papers-on-speci... |
| Description | Several presentations at the TMS2021 Annual Meeting |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | Four talks related to the project have been given at the TMS Annual Meeting (USA) - the largest metals and materials forum in the world. |
| Year(s) Of Engagement Activity | 2021 |
| Description | Symposium at TMS Annual Meeting |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Professional Practitioners |
| Results and Impact | A symposium "Ultrasonic processing of liquid and solidifying alloys" is organised at the TMS Annual Meeting in San Antonio (TX, USA) in March 2019. This is a one-day symposium with 14 presentations and expected 50-professionals audience. |
| Year(s) Of Engagement Activity | 2019 |
| Description | Talk at CAV2021 |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | A talk at the 11th International Symposium on Cavitation, May 10-13, 2021, Daejon, Korea |
| Year(s) Of Engagement Activity | 2021 |
| URL | http://cav2021.org/ |
| Description | Talk at ICSV27 |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | A talk addressing The 27th Annual Congress on Sound and Vibrations (International institute on Acoustics and Vibrations) |
| Year(s) Of Engagement Activity | 2021 |
| URL | https://www.icsv27.org/ |
| Description | Talks at TMS2022 |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | Three talks at the Light Metals programme of the TMS2022 Annual meeting - the largest metals and materials forum in the world. |
| Year(s) Of Engagement Activity | 2022 |