The cavitation erosion of ultrasonic sonotrode during large-scale metallic casting: Experiment and simulation

摘要: Abstract Ultrasonic sonotrodes play an essential role in transmitting power ultrasound into the large-scale metallic casting. However, cavitation erosion considerably impairs in-service performance of ultrasonic sonotrodes, leading to marginal microstructural refinement. In this work, behaviour castings was explored using industry-level experiments Al alloy cylindrical ingots (i.e. 630 mm diameter and 6000 mm length). When introducing ultrasound, severe found reproducibly occur at some specific positions on sonotrodes. there is no present that were not driven by electric generator. Vibratory examination showed depended vibration state Moreover, a finite element (FE) model developed simulate evolution distribution acoustic pressure 3-D solidification volume. FE simulation results confirmed significant dynamic interaction between melts only happened corresponding erosion. This work will allow for developing more advanced with better erosion-resistance, particular castings, from perspectives physics mechanical design.