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It is well known that power ultrasonic devices whilst driven under elevated excitation levels exhibit nonlinear behaviors. If no attempt is made to understand and subsequently control these behaviors, these devices can exhibit poor performance or even suffer premature failure. This paper presents an experimental method for the dynamic characterization of a commercial ultrasonic transducer for bone cutting applications (Piezosurgery® Device) operated together with a variety of rod horns that are tuned to operate in a longitudinal mode of vibration. Near resonance responses, excited via a burst sine sweep method were used to identify nonlinear responses exhibited by the devices, while experimental modal analysis was performed to identify the modal parameters of the longitudinal modes of vibration of the assemblies between 0-80 kHz. This study tries to provide an understanding of the effects that geometry and material choices may have on the nonlinear behavior of a tuned device.

Airborne power ultrasound is a green technology with a great potential for food and environmental applications, among others. This technology aims at producing permanent changes in objects and substances by means of the propagation of high-intensity waves through air and multiphase media. Specifically, the nonlinear effects produced in such media are responsible for the beneficial repercussions of ultrasound in airborne applications. Processing enhancement is achieved through minimizing the impedance mismatch between the ultrasonic radiator source and the medium by the generation of large vibration displacements and the concentration of energy radiation thus overcoming the high acoustic absorption of fluids, and in particular of gases such as air. Within this work the enhancing effects of airborne power ultrasound in various solid/liquid/gas applications including drying of solid and semi-solid substances, and the agglomeration of tiny particles in air cleaning processes are presented. Moreover, the design of new ultrasonic devices capable of generating these effects are described along with practical methods aimed at maintaining a stable performance of the tuned systems at operational powers. Hence, design strategies based on finite element modelling (FEM) and experimental methods consolidated through the years for material and tuned assembly characterizations are highlighted.

Power ultrasound (PU) is an emerging, innovative, energy saving and environmental friendly technology that is generating a great interest in sectors such as food and pharmaceutical industries, green chemistry, environmental pollution, and other processes, where sustainable and energy efficient methods are required to improve and/or produce specific effects. Two typical effects of PU are the enhancement of mass transfer in gases and liquids, and the induction of particle agglomeration in aerosols. These effects are activated by a variety of mechanisms associated to the nonlinear propagation of high amplitude ultrasonic waves such as diffusion, agitation, entrainment, turbulence, etc. During the last years a great effort has been jointly made by the Spanish National Research Council (CSIC) and the company Pusonics towards introducing novel processes into the market based on airborne ultrasonic plate transducers. This technology was specifically developed for the treatment of gas and multiphasic media characterized by low specific acoustic impedance and high acoustic absorption. Different strategies have been developed to mitigate the effects of the nonlinear dynamic behavior of such ultrasonic piezoelectric transducers in order to enhance and stabilize their response at operational power conditions. This work deals with the latter advances in the mitigation of nonlinear problems found in power transducers; besides it describes two applications assisted by ultrasound developed at semi-industrial and laboratory scales and consisting in extraction via dense gases and particle agglomeration. Dense Gas Extraction (DGE) assisted by PU is a new process with a potential to enhance the extraction kinetics with supercritical CO 2 . Acoustic agglomeration of fine aerosol particles has a great potential for the treatment of air pollution problems generated by particulate materials. Experimental and numerical results in both processes will be shown and discussed.

Nonlinear behaviour is known to exist in power ultrasonic systems. Multimodal responses, frequency modulations, hysteresis effects, bifurcations and chaos are amongst the nonlinear phenomena detected in tuned devices driven at high power. This paper investigates the effect of a cutting insert on the inherent nonlinear vibration behaviour of an ultrasonic transducer for bone surgery. The mode shape and operating mode of the tuned assembly have been simulated using finite element analysis (FEA) and validated by experimental modal analysis (EMA). The effects of temperature and power on the system nonlinear response characteristics have also been measured using a laser vibrometer (LDV) and a thermal imaging camera. Hints for the design of power ultrasonic devices with controlled vibration behaviour ensue from the work.