Upscaling environment-friendly cavitation melt treatment (UltraMelt2)

Lead Research Organisation: Oxford Brookes University
Department Name: Faculty of Tech, Design and Environment

Abstract

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Publications

10 25 50
 
Description Experimental setups have been developed to study the interaction of melt flow with ultrasonic sources with the aim to optimise the residence time and efficiency of ultrasonic processing as well as to provide data for computer simulations. A numerical model for describing acoustic flows and cavitation has been improved. In-depth understanding of the effects of impact load from collapsing of acoustically generated cavitation bubbles on crack propagation and surface fragmentation. For the first time the prime fragmentation mechanism of intermetallics due to interaction with cavitating bubbles was revealed using ultra-high speed camera observations and sophisticated acoustic measurements. The role of shockwaves upon implosion of cavitation bubbles in fragmentation of intermetallics has been demonstrated by in-situ studies and analytical modelling. Dynamics of shock waves have been acoustically characterized and optically resolved with some first time discoveries such as a characteristic propagation frequency. The unique experimental nanoindentation measurements performed in Anton Paar Laboratories (Industrial partner to this project) allowed us to apply fracture mechanics to the analysis of fragmentation of intermetallics under cavitation. Spatial and temporal mapping of the fragmentation process of floating intermetallics underpin some important statistics for controlling fragmentation and deagglomeration mechanisms of intermetallics during ultrasound important for the optimazation of the numerical models. 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

Environment

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 the 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 has prepared a new research proposal HydrAl that deals with the production of Hydrogen from liquid aluminium reducing green-house and polluting emissions while another one is due for submission with acronym H2M where concerns the mixing of immiscible alloys and metal composites.
First Year Of Impact 2022
Sector Aerospace, Defence and Marine,Chemicals,Environment,Manufacturing, including Industrial Biotechology,Transport
Impact Types Economic

 
Description Performance-driven design of Aluminium alloys for Additive Manufacturing (PAAM)
Amount £358,183 (GBP)
Funding ID EP/W006154/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 01/2023 
End 07/2026
 
Title Signal Processing Matlab code 
Description Develop an in-house Matlab code to process acoustic signals from a range of calibrated to NPL sensors. This was proven instrumental for data processing and analysis, numerical model optimazation and succesful completion of a number of journal papers. 
Type Of Material Improvements to research infrastructure 
Year Produced 2021 
Provided To Others? Yes  
Impact Without this tool we wouldn't be able to process the collected data and thus generate meaningful results. Also this tool is free to download from the http://cav-it.co.uk/ (website under development) and use for research or teaching purposes. 
 
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 was 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 were interesting. This led to a first of each kind journal paper based on the mechanical properties of intermetalics at elevated temperatures (up to 700 C) published in the Journal of Intermetallics. This will fill the gap in the existing knowledge on the behaviour of intermetallics at high temperatures, crucial for the development of high quality alloys. Collaboration with Anton Paar will continue in a new EPSRC project (PAAM) recently started.
Start Year 2018
 
Description Ultra-high speed camera observations 
Organisation University of Glasgow
Country United Kingdom 
Sector Academic/University 
PI Contribution We have experimentally identify for the first time the prime responsible mechanism (shock waves from collapsing bubbles) for the fragmentation of metallic crystals in a sonicated environment.
Collaborator Contribution Allowed us to use their state of the art laser-induced bubble facility providing knowledge and expertise
Impact Collaboration with Glasgow University led to the publications of 4 journal papers in the Journals of Fluid Mechanics (1) and Ultrasonics Sonochemistry (3) 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 ESS-JSS-AOSS 1st JOINT SONOCHEMISTRY CONFERENCE (ONLINE) 
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 Two presentations at this major Sonochemistry event
Year(s) Of Engagement Activity 2021
 
Description Editing a Special Issue of Materials (www.mdpi.com/journal/materials) 
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 Dr I., Tzanakis and Prof. D. Eskin acted as guest editors for a Special Issue "Ultrasonic Cavitation Treatment of Metallic Alloys" of Materials (journal ISSN 1996-1944, IF 2.97) with 6 invited and review papers published in 2019.
Year(s) Of Engagement Activity 2019
URL https://www.mdpi.com/journal/materials/special_issues/ultrasonic_metallic_alloys
 
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 9.336) 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 attracted 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 Invited talk at the Institute of Physics (IoP) Group Tutorial Day (2023) in London - Acoustics in Action 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Postgraduate students
Results and Impact The tutorial day attracted a diverse audience mainly students (~30) from Imperial, Glasgow, Surrey, Oxford Brookes and Oxford Universities as well as academic professionals and industry representatives across the UK. On this tutorial day, novel applications, up-scaling and cavitation metrology were discussed which sparked questions and discussions afterwards, especially among PhD students and other Post-docs.
Year(s) Of Engagement Activity 2023
URL https://iop.eventsair.com/pagtd2023/
 
Description Invited talk in the 184th Meeting of the Acoustical Society of America 
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 An invited talk in the annual event of the Acoustical Society of America (Chicago, 8-12 May 2023).
Year(s) Of Engagement Activity 2022
 
Description Invited talk in the ERC Workshop on Cavitation Exploitation in Ljubljana, Slovenia. 
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 Iakovos was invited to present a talk at the ERC Workshop on Cavitation Exploitation in Ljubljana, Slovenia. The title of his presentation was 'Ultrasonic Cavitation Processing of Multi-functional Materials: Fundamentals and Applications.' His talk generated significant interest from the audience, especially towards the optimization and control of ultrasonic technologies
Year(s) Of Engagement Activity 2023
URL https://www.matevzdular.com/workshop-2023/
 
Description Participation and talk in the 17th Meeting of the European Society of Sonochemistry 
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 One presentation in this major event, which sparked questions and discussions on the fundamentals of bubble dynamics and cavitation processes due to new insights/knowledge that was discovered in this project
Year(s) Of Engagement Activity 2022
 
Description Participation in CAV 2021 Symposium 
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 One presentation on the 11th International Symposium on Cavitation 2021 (CAV2021), Virtual Conference from 10 to 13 May 2021 in Korea
Year(s) Of Engagement Activity 2021
 
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 Special Issue 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact A Special Issue on Ultrasonic Cavitation Treatment (UST) of Metallic Alloys for the Journal of Materials (ISSN 1996-1944, IF 2.97) was edited by Iakovos Tzanakis and Dmitry Eskin with contributions (6 invited and review papers published in 2020) from leading research groups around the globe.

Special Issue scrutinise the use of UST in technology of high-quality metallic alloys with improved mechanical properties, assess the driving mechanisms of cavitation-induced effects, such as grain refinement, degassing, wetting, particle distribution etc. and examines the possibility of achieving high efficiency in processing of large melt volumes through technological approaches for the commercial implementation.
Year(s) Of Engagement Activity 2020
URL https://www.mdpi.com/journal/materials/special_issues/ultrasonic_metallic_alloys
 
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 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