Feasibility study on multifrequency excitation of the melt pool during ultrasonic-assisted laser beam welding.

The constantly increasing demands on components and their resource-efficient production require new strategies in modern process chains. The Collaborative Research Centre (CRC) 1153 "Tailored Forming" is working on the production of hybrid solid components made from joined semi-finished products with subsequent forming. Laser beam welding with ultrasonic assistance has proven to be advantageous in the production of semi-finished products due to the active influence on the microstructure as a result of the excitation. In this work, the feasibility of extending the monofrequency excitation of the melt pool used so far during welding to a multifrequency excitation is investigated. Results from simulations and experiments show that a multi-frequency excitation of the weld pool can be effectively realised. Furthermore, it is shown that a combination of previously separately used excitation methods (positioning of the melt pool in the vibration node and in the vibration antinode, respectively) with two different frequencies is successful and leads to a combination of effects as desired, what can be seen from micrographs.

Experimental Investigation of the Rapid Fabrication of Micron and Submicron Structures on Polymers Utilizing Ultrasonic Assisted Embossing.

Small-scale optical components with micron or submicron features have grown in popularity in recent years. High-quality, high-efficient, and cost-effective processing approaches for polymer optics mass production are an urgent need. In this study, ultrasonic vibration will be introduced in embossing. The major advantage is that the required energy can be provided for process times ranging from a few hundred milliseconds to a few seconds, and that the process energy is provided at exactly the required location so that the structures in the surrounding area are not affected. Due to the strong correlation between electrical impedance and the temperature of the material, a novel impedance-based control strategy has been utilized for precisely controlling ultrasonic vibration during the embossing process. The investigation used two types of stamps with grating line widths of 4 µm and 500 nm, respectively. As a result, an embossing time of less than a few seconds was accomplished and a uniform embossed surface with an average fill rate of more than 75% could be achieved.

Dynamic Acoustic Levitator Based On Subwavelength Aperture Control.

Acoustic levitation provides a means to achieve contactless manipulation of fragile materials and biological samples. Most acoustic levitators rely on complex electronic hardware and software to shape the acoustic field and realize their dynamic operation. Here, the authors introduce a dynamic acoustic levitator that is based on mechanically controlling the opening and (partial) closing of subwavelength apertures. This simple approach relies on the use of a single ultrasonic transducer and is shown to permit the facile and reliable manipulation of a variety targets ranging from solid particles, to fluid and ferrofluidic drops. Experimental observations agree well with numerical simulations of the Gor'kov potential. Remarkably, this system even enables the generation of time-varying potentials and induces oscillatory and rotational motion in the levitated objects via a feedback mechanism between the trapped object and the trapping potential. This is shown to result in long distance translation, in-situ rotation and self-modulated oscillation of the trapped particles. In addition, dense ferrofluidic droplets are levitated and transformed inside the levitator. Controlling subwavelength apertures opens the possibility to realize simple powerful levitators that nevertheless allow for the versatile dynamic manipulation of levitated matter.

Air-Coupled Ultrasound Time Reversal (ACU-TR) For Subwavelength Nondestructive Imaging.

Air-coupled ultrasound (ACU) is increasingly used for nondestructive testing (NDT). With ACU, no contact or coupling agent (e.g., water and ultrasound gel) is needed between transducers and test sample, which provides high measurement reproducibility. However, for testing in production, a minimum separation is often necessary between the sample and the transducers to avoid contamination or transducer damage. Due to wave diffraction, the collimation of the ultrasound beam decreases for larger propagation distances, and ACU images become blurred and show lower defect lateral resolution with increasing sample-transducer separation. This is especially critical to thick composites, where large-size planar sources are used to bridge the large ACU transmission loss with good collimation. In this work, ACU reradiation in unbounded media is extended to NDT of multilayered composites. The extended method is named ACU time reversal (ACU-TR) and significantly improves the defect resolution of ACU imaging. With ACU-TR, the complete pressure distribution radiated by large ACU source is measured with point receivers (RXs) in one plane arbitrarily separated from the sample. By applying acoustic holography physics, it is then possible to quantitatively reconstruct the pressure field directly at arbitrary sample defect planes, which compensates for undesired diffraction phenomena and improves minimum detectable defect size, thereby achieving subwavelength lateral resolution. We tested the method on complex wood-based composite samples based on the ACU far-field measurements at a separation of 160 mm between the sample and the RX transducer. With the proposed method, it is possible to detect surface defects as well as inner defects within composite boards. In the future, by using point RX arrays instead of a scanned microphone, both data acquisition and evaluation can be potentially implemented in real time.

Self-sensing cavitation detection in ultrasound-induced acoustic cavitation.

The generation of cavitation by ultrasound is used in a large number of processes in different scientific and industrial applications. Chemical reactions are made possible or accelerated by locally occurring high temperatures and pressures generated by the collapse of cavitation bubbles. Mixing or separating substances, emulsification, ultrasonic cleaning, degassing, and microbiological treatment of fluids are some more applications for ultrasonic generated cavitation. In most of these applications, an optical examination of the events within the cavitating medium is not possible. Non-transparent media or closed containers prevent an optical process monitoring. In addition, the use of sensors is often impossible for cost reasons, limited construction space or disturbance of the process. In order to still enable process monitoring, the authors follow a novel approach: the analysis of the electrical signals of the ultrasound transducer used for cavitation generation. The current signal of the ultrasound transducer is inspected for frequency components, known as acoustic cavitation indicators. For this, the time signal is recorded and transferred to the frequency domain for further processing and evaluation. In previous studies, acoustical sensors like hydrophones or microphones were used as reference for the self-sensing technique. In order to link cavitation events inside the fluid container to cavitation indicators in the current signal, a photo study of the cavitation events inside a transparent water container is conducted. In contrast to previous self-sensing attempts, the ultrasound transducer's transfer characteristic is also considered. The evaluation of the acquired data shows that a frequency component which is 3/2 times the driving frequency (∼30 kHz) can be used to determine the onset of transient cavitation. Once the transient cavitation threshold has been exceeded, broad band noise levels show a good correlation with cavitation intensity.

Numerical analysis of intracochlear mechanical auditory stimulation using piezoelectric bending actuators.

Cochlear implantation can restore a certain degree of auditory impression of patients suffering from profound hearing loss or deafness. Furthermore, studies have shown that in case of residual hearing, patients benefit from the use of a hearing aid in addition to the cochlear implant. The presented studies aim at the improvement of this electromechanical stimulation (EMS) approach by substituting the external hearing aid by an internal stimulus provided by miniaturized piezoelectric actuators. Finite element analyses are performed in order to derive fundamental guidelines for the actuator layout aiming at maximal mechanical stimuli. Further analyses aim at investigating how the actuator position inside the cochlea influences the basilar membrane oscillation profile. While actuator layout guidelines leading to maximized acoustic stimuli could be derived, some of these guidelines are of complementary nature suggesting that further studies under realistic boundary conditions must be performed. Actuator positioning inside the cochlea is shown to have a significant influence on the resulting auditory impression of the patient. Based on the results, the main differences of external and internal stimulation of the cochlea mechanism are identified. It is shown that if the cochlea tonotopy is considered, the frequency selectivity resulting from the mechanical cochlea stimulus may be improved.

Capability evaluation of ultrasonic cavitation peening at different standoff distances.

Ultrasonic cavitation peening is a novel surface treatment technology which utilizes the effect of cavitation bubble collapses to improve the properties of metal surfaces. In order to obtain high impact during ultrasonic cavitation peening, a small standoff distance between a sound radiator and a rigid reflector (the surface of treated specimen) is necessary. However, the effects of different standoff distances on the capability of ultrasonic cavitation peening are not yet clear. In this paper, a simplified model was developed to evaluate the cavitation capability at different standoff distances. Meanwhile, to validate the theoretical model, the plastic deformation or erosion on the peening surface before and after treatment were compared. It was found that at a very small standoff distance the impact pressure generated by cavitation bubbles did not cause much deformation or erosion, as the dynamics of cavitation bubbles was limited. At a large standoff distance, due to much attenuation of sound propagation in the bubbly liquid, little impact pressure was generated by the collapse of cavitation bubbles and reached the treated surface. A fixed vibration amplitude, however, corresponded to a standoff distance which caused the largest deformation or erosion on the treated surface.

Determination of optimal excitation patterns for local mechanical inner ear stimulation using a physiologically-based model.

Within the field of hearing prosthetics it is known that patients with sufficient residual hearing benefit from the simultaneous employment of hearing aid and cochlear implant. Several attempts have been proposed to combine the sources of the corresponding acoustic and electric stimuli in a single, implantable device. However, since only little is known about the effect of also applying the acoustic stimulus locally from within the inner ear, the current state of research lacks detailed knowledge on the optimal stimulation at the corresponding bionic interface. Within this manuscript, a simple but yet physiologically-based inner ear model is presented which was designed specifically for the analysis of local acoustic or mechanical inner ear stimulation. A detailed model analysis is performed showing that it is capable of mirroring the known mechanical phenomena of this particular stimulation approach. Using the model, it is demonstrated how amplitude and phase shift values of stimuli applied from within the inner ear should be chosen for optimal inner ear stimulation.

Piezoelectric self-sensing system for tactile intraoperative brain tumor delineation in neurosurgery.

Mechanical characteristics of tumor and healthy tissue in the brain differ but slightly. The task of designing a system that is able to differentiate tissue dignity with high sensitivity is of great importance in neurosurgery. Even when localization of tumor by use of preoperative imaging techniques provides the surgeon with valuable information to decide where and what to resect, the brain shift due to change in pressure during skull opening demands the surgeon to define the limits of the tumor using tactile and visual differentiation. This paper contains a general description of the tactile sensor system based on a piezoelectric bimorph. The main parts of the measurement system are described and the selection of the electrical parameters for tactile differentiation is justified. Results are discussed for a series of measurements at different concentrations in gelatin phantoms.