Frictional characteristics of sheet metals with superimposed ultrasonic vibrations

The forming performance of sheet metals in the deep-drawing process with ultrasonic vibrations can be improved by the surface effect between the sheet metal and the die.A sheet metal friction test with ultrasonic vibrations is performed to explore the cause of the surface effect.The frictional characteristics are investigated,and the corresponding friction expressions are established based on the contact mechanics and the elastic–plastic contact model for rough surfaces.Friction is caused by the elastic–plastic deformation of contacting asperities under normal loads.The actual contacting region between two surfaces increases with normal loads,whereas the normal distance decreases.The normal distance between the contacting surfaces is changed,asperities generate a tangential deformation with ultrasonic vibrations,and the friction coefficient is eventually altered.Ultrasonic vibrations are applied on a 40Cr steel punch at the frequency of 20 kHz and the amplitude of 4.2μm.In the friction tests,the punch is perpendicular to the surface of the magnesium alloy AZ31B sheet metals and is sliding with a relative velocity of 1 mm/s.The test results show that the friction coefficient is decreased by approximately 40%and the theoretical values are in accordance with the test values;Ultrasonic vibrations can clearly reduce wear and improve the surface quality of parts.

Ultrasonic Nebulizer Assisted LIBS: a Promising Metal Elements Detection Method for Aqueous Sample Analysis

A newly developed approach for trace metal elements detection for aqueous samples analysis is presented in this paper. The idea of this approach is to improve ablation efficiency by transforming the liquid sample into a dense cloud of droplets using an ultrasonic nebulizer. The resulting droplets are then subjected to analysis by laser induced breakdown spectroscopy （LIBS）. A purpose-built ultrasonic nebulizer assisted LIBS （UN-LIBS） system has been applied to the analysis of aqueous samples at trace levels of concentration. Experimental investigations of solution samples were carried out with various dissolved trace metal elements （Mn, Zn, Cu, Pb, Fe, Mg and Na） using this approach. The characteristics of UN-LIBS signal of the elements were investigated regarding the lifetime and S/B ratio and the calibration curves for trace metal elements analyses. The obtained LODs are comparable or much better than the LODS of the reported signal enhancement approaches when the laser pulse energy was as low as 30 mJ. The good linearity of calibration curves and the low LODs shows the potential ability of this method for metal elements analysis application. The density of the electrons was calculated by measuring the Stark width of the line of Ha. The possible mechanism of the LIBS signal enhancement of this approach was briefly discussed.

Modifying Behaviors of Ultrasonic Irradiation and Rare Earth Metal Cerium on Electroless Co-Ni-B Alloy Coating

By plasma transmitting spectrograph,electron energy spectrometry,X-ray diffractometry,transmission electron microscopy and micro-hardometry,the effects of ultrasonic irradiation and rare earth metal cerium on the depositing speed,chemical composition,crystal structure and microhardness of electroless Co-Ni-B alloy coating were inspected and analyzed. The results show that cerium and ultrasonic irradiation can evidently raise the depositing speed of electroless Co-Ni-B alloy. The cerium content of electroless Co-Ni-B-Ce alloy coating also increases after ultrasonic irradiation applied to electroless Co-Ni-B plating process. Under the action of ultrasonic irradiation and rare metal cerium,the chemical composition of electroless Co-Ni-B alloy coating is changed. Electroless Co-Ni-B alloy with amorphous structure is transformed to electroless Co-Ni-B-Ce alloy with microcrystalline in general state and electroless Co-Ni-B-Ce alloy with crystalline structure in ultrasonic irradiation. In this way microhardness of the coatings increases remarkably.

Research on arc characteristics and metal transfer modes of ultrasonic assisted GMAW process

Ultrasonic assisted GMAW （U-GMAW） method is a novel process, which combines the ultrasonic wave with gas metal arc welding to improve the process stability and weld quality. The U-GMAW system is developed and the ultrasonic wave is applied by means of acoustic radiation. The arc characteristics and metal transfer modes are studied in comparison with conventional GMAW process. The arc plasma is compressed and the arc length is shorter than that in conventional GMAW process after the ultrasonic is applied onto the arc. The parameter range of short-circuiting mode is extended and the range of unstable transfer is minimized. The changes in arc characteristics are responsible for changes in metal transfer modes.

Ultrasonic vibration assisted tungsten inert gas welding of dissimilar metals 316L and L415

Ultrasonic vibration assisted tungsten inert gas welding was applied to joining stainless steel 316 L and low alloy high strength steel L415.The effect of ultrasonic vibration on the microstructure and mechanical properties of a dissimilar metal welded joint of 316 L and L415 was systematically investigated.The microstructures of both heat affected zones of L415 and weld metal were substantially refined,and the clusters ofδferrite in traditional tungsten inert gas(TIG)weld were changed to a dispersive distribution via the ultrasonic vibration.The ultrasonic vibration promoted the uniform distribution of elements and decreased the micro-segregation tendency in the weld.With the application of ultrasonic vibration,the average tensile strength and elongation of the joint was improved from 613 to 650 MPa and from 16.15%to31.54%,respectively.The content ofΣ3 grain boundaries around the fusion line zone is higher and the distribution is more uniform in the ultrasonic vibration assisted welded joint compared with the traditional one,indicating an excellent weld metal crack resistance.

Conjugate Heat Transfer Analysis of an Ultrasonic Molten Metal Treatment System

In piezoceramic ultrasonic devices,the piezoceramic stacks may fail permanently or function improperly if their working temperatures overstep the Curie temperature of the piezoceramic material.While the end of the horn usually serves near the melting point of the molten metal and is enclosed in an airtight chamber,so that it is difficult to experimentally measure the temperature of the transducer and its variation with time,which bring heavy difficulty to the design of the ultrasonic molten metal treatment system.To find a way out,conjugate heat transfer analysis of an ultrasonic molten metal treatment system is performed with coupled fluid and heat transfer finite element method.In modeling of the system,the RNG model and the SIMPLE algorithm are adopted for turbulence and nonlinear coupling between the momentum equation and the energy equation.Forced air cooling as well as natural air cooling is analyzed to compare the difference of temperature evolution.Numerical results show that,after about 350 s of working time,temperatures in the surface of the ceramic stacks in forced air cooling drop about 7 K compared with that in natural cooling.At 240 s,The molten metal surface emits heat radiation with a maximum rate of about 19 036 W/m2,while the heat insulation disc absorbs heat radiation at a maximum rate of about 7922 W/m2,which indicates the effectiveness of heat insulation of the asbestos pad.Transient heat transfer film coefficient and its distribution,which are difficult to be measured experimentally are also obtained through numerical simulation.At 240 s,the heat transfer film coefficient in the surface of the transducer ranges from–17.86 to 20.17 W/（m2？K）.Compared with the trial and error method based on the test,the proposed research provides a more effective way in the design and analysis of the temperature control of the molten metal treatment system.

Experimental Study of Liquid Metal Flow for the Development of a Contact-Less Control Technique

The article presents an experimental study on the flow of an eutectic gallium alloy in a cylindrical cell,which is placed in an alternating magnetic field.The magnetic field is generated by a coil connected to an alternating current source.The coil is located at a fixed height in such a way that its plane is perpendicular to the gravity vector,which in turn is parallel to the axis of the cylinder.The position of the cylinder can vary in height with respect to the coil.The forced flow of the considered electrically conductive liquid is generated due to the action of the localized electromagnetic force.It is assumed that under the action of the alternating magnetic field,the liquid is heated uniformly,and the resulting heat is quickly absorbed by the forced flow,so that liquid free convection can be neglected.The experiment is carried out using an ultrasonic Doppler anemometer.One transducer is installed in the axially located cylinder sluice and the other transducer is placed in the near-wall region.According to the results,a velocity profile,corresponding to a two-tori flow pattern can be hardly obtained in the low frequency range of the power supply.However,this is possible in the high frequency range.The average velocity profiles depend essentially on the location of the coil relative to the cell.The spectral analysis of velocity signals shows that the amplitude of the velocity pulsations is comparable to the average value of the flow velocity.Such experimental results and their verification through comparison with numerical calculations are intended to support the development of new methods for reducing the intensity of vortex flows during the electromagnetic separation of impurities through an electromagnetic induction mechanism(able to produce an electromotive force that displaces particles).

Application of ultrasonic to speciation analysis of heavy metals in soil

In order to reduce the operation time and improve the extraction efficiency, ultrasonic energy by means of ultrasonic bath was used to the modified Tessier sequential extraction for speciation analysis of heavy metals in soil. Extractable contents of Cu, Fe, Mn, Ni, Pb and Zn were measured by atomic absorption spectroscopy(AAS). The merit of the ultrasonic extraction(UE) applied to the modified Tessier method is not only that the operation time for the first 4 fractions was reduced from ca.18 h to 8 h, comparing with conventional extraction(CE), but also the extraction efficiency was higher. The results for both of UE and CE were consistent. The extractable Cu, Ni and Zn in the sample No.1 were mainly associated with the third fraction(Fe-Mn oxides fraction), and fourth fraction(organic matter fraction) in the sample No.2. The extractable Fe and Mn were all mainly associated with the third fraction, and Pb the fourth fraction in both of the samples. The effects of concentration of hydroxylamine chloride on the capability for the extraction of studied metals were also studied.

Ultrasonic-enhanced Stereoselective Debromination of vic-Dibromides to Alkenes with Metallic Zinc Powder in Aqueous Media

Carbon-carbon double bond functional groups are often protected through a popular bromination/debromination method because of their reactivity. An ultrasonic-enhanced stereoselective debromination of vic-dibromides with metallic zinc powder in aqueous media has been developed, which generates E-alkenes with excellent yields. The reactivity of vic-dibromides decreases in the order of 1,2-dibromo-1,2-diphenylethane>1,2-dibromo-1-phenylethane>1,2-dibromo-1,2-dialkylethane.

Damage analysis for particle reinforced metal matrix composite by ultrasonic method

The damage characteristic of particle reinforced metal matrix composite (PMMC) was studied by ultrasonic non-destructive evaluation method. After the sample was damaged induced by tensile load, the ultrasonic wave that propagated in the sample were collected. The damage parameter was defined by ultrasonic parameter and the wave signals were analyzed by correlation method. The results show that with the increase of tensile load, the damage parameter increases and the correlation coefficient decreases. The fracture section morphologies of PMMC under tensile load were observed by SEM. It is found that there are many concaves in the metal matrix. Therefore the damage evolution can be concluded. The initial damage is induced by void nucleation, growth and subsequent coalescence in the matrix or interface separation.

Ultrasonically Assisted Regioselective Nitration of Aromatic Compounds in Presence of Certain Group V and VI Metal Salts

Ultrasonically assisted nitration reactions (USANR) with anilides, moderately activated and non-activated aromatic compounds underwent smoothly and afforded good yields of products with high regio selectivity. Observed longer reaction times (6 - 8 hrs.) in metal catalyzed reactions reduced to (1 - 2 hrs.) under sonication. When ortho position is blocked para derivatives are obtained, and ortho nitro products are obtained when para position is blocked. In case of USANR of aromatic carbonyl and related compounds the effect of sonication is much more effective. The reactions could be completed only in few minutes.

Smart decontamination device for small-size radioactive scrap metal:using abrasion pin in rotating magnetic field and ultrasonic wave cleaner

A smart decontamination device is developed for small-size radioactive scrap metal(SSRSM)arisen from nuclear facilities.The abrasion pin in rotating magnetic field and ultrasonic wave cleaner are used for solving the problems of the second decontamination and high treatment cost.At first,the decontamination efficiency of each device is improved by upgrading the design.Optimal operating conditions are determined for each device.Next,both techniques are applied sequentially.Experimental results show that the efficiency of combined decontamination device is higher than that of each device.With the use of the developed device,the various SSRSMs are decontaminated for 15 min treatment in magnetic abrasion device and15 min treatment in ultrasonic cleaning device.Decontamination index ranges from18 to 56.Absolute values of all decontaminated samples are below the background value.

Sensitivity of Nanostructured Iron Metal on Ultrasonic Properties

The present investigation is focused on the influence of the nanocrystalline structure of pure iron metal on the ultrasonic properties in the temperature range 100 - 300 K. The ultrasonic attenuation due to phonon- phonon interaction and thermoelastic relaxation phenomena has been evaluated for longitudinal and shear waves along , and crystallographic directions. The second-and third-order elastic constants, ultrasonic velocities, thermal relaxation, anisotropy and acoustic coupling constants were also com- puted for the evaluation of ultrasonic attenuation in this temperature scale. The direction is most ap- propriate to study longitudinal sound waves, while , direction are best to propagate shear waves due to lowest values of attenuation in these directions. Other physical properties correlated with obtained results have been discussed.

Development of an Ultrasonic Motor That Uses an Inchworm Shaped Deformation of a Metallic Plate

At the present time, ultrasonic motors have been developed for a variety of purposes such as linear motion drives and rotational drives. The elaboration of an ultrasonic motor is time-consuming, because it is developed adapting on its application. In this study, a new ultrasonic motor structure that combines a piezoelectric element and a metallic plate is elaborated. The driving principle of this motor is that the metal plate is bent to an inchworm shape and rotates the rotor when the piezoelectric element is stretched. The objective of this study is to verify the functioning of the new motor experimentally.

Characterization of Ultrasonic Metal Welding Process

The ultrasonic welding process for wires is being largely used on industry mainly on applications that involve the connectionbetween similar or different metals. The biggest benefit of this technology is the possibility to perform the weld without additionmaterials, like terminals, metal rings or tapes. Manufacturing of wiring harnesses demands a significant amount of joining, such aswelding, crimping or soldering, to fulfill the desired layout of the harnesses and capacity requirements, but conventional connectionprocesses, face difficulties in joining multiple cross sections mainly due to the characteristics of the processes and equipment in use.Ultrasonic metal welding process overcomes these issues due to the solid-state characteristics inherent to the process itself that includethe excellent electrical properties of the joint. Several researches on ultrasonic metal welding are being done to define the fundamentalmechanisms behind this process and it is being seen that they are completely dependent on the cross section to be welded. With thisresearch we are trying to develop methods for process characterization and define acceptable quality parameters in this process. Themain topics addressed in this paper are the characterization the weld formation using copper-to-copper wires using optical microscopyand the analysis of insulation material when submitted to different thermal conditions.

Microstructure and properties of rheo-diecast Al-20Si-2Cu-1Ni-0.4Mg alloy with direct ultrasonic vibration process

The microstructure and properties of Al-20Si-2Cu-1Ni-0.4Mg alloy fabricated with semi-solid rheo-diecasting process were studied.A newly developed direct ultrasonic vibration process(DUV process) was used in the preparation of the semi-solid slurry of this alloy.The results show that the primary Si particles in this alloy is about 20 μm in size under DUV for 90 s in the semi-solid temperature range,compared to about 30 μm in the alloy without DUV.It is discovered that the primary Si particles distribute more homogeneously and have regular shape,but have lower volume fraction after DUV.The tensile strength at room temperature is about 310 MPa,and the tensile strength and elongation of the semi-solid die castings are increased by 34% and 45%,respectively,compared with the traditional liquid die castings.The high-temperature tensile strength at 300 ℃ of this high Si aluminum alloy reaches 167 MPa,and the coefficient of thermal expansion is 17.37×10-6/℃ between 25 and 300 ℃.This indicates that this high Si content Al-Si alloy produced with the DUV process is suitable to be used in the manufacture of pistons or other heat-resistant parts.

Development and preliminary study on the ultrasonic assisted GMAW method

The ultrasonic assisted GMAW （U-GMAW） method is proposed to achieve a more stable welding process and better weld quality. Tbe U-GMA W system is dereloped, which consists of power supplies, ultrasonic vibration system and specially designed u＇elding torch. The U-GMA W process and eonventional GMA W process are compared through bead-on-plate welding. The weld beads arc continuous and well protected, while the weld surface appearances by GMA W and U-GMA W are apparently diffierent. The metal transfe ,node changes from globular transfer to short-circuiting transfer after ultrasonic wave is applied onto the arc.

Microstructure and microtexture evolution of aluminum alloy 3003 under ultrasonic welding process for embedding SiC fibre

Ultrasonic welding process can be used for bonding metal foils which is the fundament of ultrasonic consolidation （UC）. UC process can be used to embed reinforcement fibres such as SiC fibres within an aluminum matrix materials. In this research we are investigating the phenomena occurring in the microstructure of the parts during ultrasonic welding process to obtain better understanding about how and why the process works. High-resolution electron backscatter diffraction （ EBSD ） is used to study the effects of the vibration on the evolution of microstructure in AA3003. The inverse pole figures （IPF） and the correlated misorientation angle distribution of the mentioned samples are obtained. The characteristics of the crystallographic orientation, the grain structure and the grain boundary are analyzed to find the effect of ultrasonic vibration on the microstructure and microtexture of the bond. The ultrasonic vibration will lead to exceptional refinement of grains to a micron level along the bond area and affect the crystallographic orientation. Ultrasonic vibration results in a very weak texture. Plastic flow occurs in the grain after welding process and there is additional plastic flow around the fibre which leads to the fibre embedding.

Nano-SiC_P particles distribution and mechanical properties of Al-matrix composites prepared by stir casting and ultrasonic treatment

Nano-ceramic particles are generally difficult to add into molten metal because of poor wettability. Nano-SiC particles reinforced A356 aluminum alloy composites were prepared by a new complex process, i.e., a molten-metal process combined with high energy ball milling and ultrasonic vibration methods. The nano particles were β-SiCp with an average diameter of 40 nm, and pre-oxidized at about 850 ℃ to form an oxide layer with a thickness of approximately 3 nm. The mm-sized composite granules containing nano-SiCp were firstly produced by milling the mixture of oxidized nano-SiCp and pure Al powders, and then were remelted in the matrix-metal melt with mechanical stirring and treated by ultrasonic vibration to prepare the composite. SEM analysis results show that the nano-SiC particles are distributed uniformly in the matrix and no serious agglomeration is observed. The tensile strength and elongation of the composite with 2wt.% nano-SiCp in as-cast state are 226 MPa and 5.5％, improved by 20％ and 44％, respectively, compared with the A356 alloy.

Microstructural Analysis of Ultrasonic Welded AA6061 by Electron Backscattered Diffraction

Ultrasonic welding can be used to join plastic and metal through high-frequency (more than 20 kHz) acoustic vibrations. Aluminium alloy is widely used in electronics, automotive and aerospace. The mechanical vibrations used during ultrasonic metal welding are introduced horizontally. During ultrasonic metal welding, a complex process is triggered involving static forces, oscillating shearing forces and a moderate temperature increase in the welding area. As the energy is introduced to the weld zone, there are three important phenomena occurring which are surface effect, volume effect and thermal effect. As it is known, microstructure is directly linked to the mechanical properties including fatigue resistance, fatigue life and fracture strength. So the microstructure analysis is important to evaluate the ultrasonically welded aluminium alloy’s properties. Also, mechanical properties of metal sheets, such as plastic anisotropy and formability, can be improved by a proper crystallographic texture control. That means the texture has great influence on the plastic anisotropy of the final recrystallized sheets. Optical microscopy (OM) can be used for showing the grain size and grain shape. However, to examine the relationship between mechanical behaviour and microstructure of the weldment, optical microscopy(OM) is not sufficient. OM cannot delineate a grain structure in the weld zone. The etched surface exhibited granularity at the micron level, but it was not clear if that reflected the grain structure. Electron backscatter diffraction (EBSD) in an SEM has become the most widely used technique for determination of microtexture. In this research, high-resolution electron backscatter diffraction is used to study the effects of the vibration on the evolution of microstructure in AA6061. The orientation image maps (OIM), polar figures (PF), and orientation distribution functions (ODF) of the samples are obtained. The characteristics of the crystallographic orientation, the grain structure and the grain boundary are analysed to find the effect of ultrasonic vibration on the microstructure and texture of the bond. The ultrasonic vibration will lead to exceptional refinement of grains to a micron level along the bond area and affect the crystallographic orientation. The grain size of upper foil is much smaller than that of the lower foil. And ultrasonic vibration results in a very weak texture with some characteristic intensity of a rotated cube-orientation and the Brass-orientation and S-orientation. In the lower foil, there is no much influence of the ultrasonic vibration. So there is very strong cube orientation in the lower foil.