ABSTRACT
A new contactless ultrasonic sonotrode method was previously designed to provide cavitation conditions inside liquid metal. The oscillation of entrapped gas bubbles followed by their final collapse causes extreme pressure changes leading to de-agglomeration and the dispersion of oxide films. The forced wetting of particle surfaces and degassing are other mechanisms that are considered to be involved. Previous publications showed a significant decrease in grain size using this technique. In this paper, the authors extend this research to strength measurements and demonstrate an improvement in cast quality. Degassing effects are also interpreted to illustrate the main mechanisms involved in alloy strengthening. The mean values and Weibull analysis are presented where appropriate to complete the data. The test results on cast Al demonstrated a maximum of 48% grain refinement, a 28% increase in elongation compared to 16% for untreated material and up to 17% increase in ultimate tensile strength (UTS). Under conditions promoting degassing, the hydrogen content was reduced by 0.1 cm3/100 g.
ABSTRACT
A high frequency tuned electromagnetic induction coil is used to induce ultrasonic pressure waves leading to cavitation in alloy melts. This presents an alternative 'contactless' approach to conventional immersed probe techniques. The method can potentially offer the same benefits of traditional ultrasonic treatment (UST) such as degassing, microstructure refinement and dispersion of particles, but avoids melt contamination due to probe erosion prevalent in immersed sonotrodes, and it can be used on higher temperature and reactive alloys. An added benefit is that the induction stirring produced by the coil, enables a larger melt treatment volume. Model simulations of the process are conducted using purpose-built software, coupling flow, heat transfer, sound and electromagnetic fields. Modelling results are compared against experiments carried out in a prototype installation. Results indicate strong melt stirring and evidence of cavitation accompanying acoustic resonance. Up to 63% of grain refinement was obtained in commercial purity (CP-Al) aluminium and a further 46% in CP-Al with added Al-5Ti-1B grain refiner.
