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Data availability: Data will be made available on request. Copyright © 2023 The Authors. This work deals with the measurement of mechanical properties of single and polycrystalline Al3Zr specimens from ambient to elevated temperatures using nano-indentation experiments. In this study, we employed three kinds of intermetallic specimens produced from Al3Zr crystals chemically extracted from an Al-3 wt% Zr alloy. The properties such as elastic modulus and hardness were determined under quasistatic loading conditions. Constant multicycle indentation testing (MCT) was further performed using a Vickers indenter to understand the fatigue response of intermetallics at high load low cycle conditions. The results showed that hardness and elastic modulus of Al3Zr intermetallics depended on the crystal structure/orientation, with polycrystalline samples showing higher elastic modulus than single crystal specimens at room temperature conditions. MCT experiments revealed that contact pressure of more than 7 GPa was needed to fracture a crack-free crystal under dynamic loading conditions. Consequently the properties of intermetallics at temperatures up to 700 °C were determined for the first time, using high-temperature nano-indentation technique. Elevated temperature measurements indicated that intermetallics had high creep resistance at low and intermediate temperatures, but exhibited significant plastic deformation and creep close to the melting point of pure aluminium. UK Engineering and Physical Sciences Research Council (EPSRC) UltraMelt2 project with grants EP/R011001/1, EP/R011095/1 and EP/R011044/1.

In this work, we study how ultrasonic cavitation melt treatment (UST) affects the temperature distribution, sump profile, and resulting microstructure in the direct-chill (DC) casting of an AA6008 aluminum alloy. Two 152 mm diameter billets were cast; one was treated with UST (UST-DC casting) in the hot top while the other was not (conventional DC casting). To investigate the temperature distribution, temperature was measured at multiple points in both billets. The sump profile was visualized by pouring Zn into the sump during casting. The microstructure was analyzed by measuring the grain size of as-cast billets. A numerical model of DC casting and UST-DC casting has been validated with the temperature measurements across the billets, and the experimental results agrees well with the numerical model. It is found that the sump profile quantification with thermocouple measurements is more accurate and less prone to interpretation than with Zn tracing. Numerical simulation results show that UST application in the hot top with sonotrode position at 20 mm above the graphite ring level depresses the liquidus isotherm but does not affect the solidus isotherm, resulting in a thinner transition region compared with conventional DC casting. Grain structure analysis verifies that structure refinement with UST has been achieved at the given sonotrode position. The strongest grain refinement was at the center of the billet with the average grain size 50% smaller than that without UST. The results are discussed in terms of the known mechanisms of UST, i.e. dendrite fragmentation and deagglomeration of nucleating substrates.

Ultrasonic treatment is effective in deagglomerating and dispersing nanoparticles in various liquids. However, the exact deagglomeration mechanisms vary for different nanoparticle clusters, owing to different particle geometries and inter-particle adhesion forces. Here, the deagglomeration mechanisms and the influence of sonotrode amplitude during ultrasonication of multiwall carbon nanotubes in de-ionized water were studied by a combination of high-speed imaging and numerical modeling. Particle image velocimetry was applied to images with a higher field of view to calculate the average streaming speeds distribution. These data allowed direct comparison with modeling results. For images captured at higher frame rates and magnification, different patterns of deagglomeration were identified and categorized based on different stages of cavitation zone development and for regions inside or outside the cavitation zone. The results obtained and discussed in this paper can also be relevant to a wide range of carbonaceous and other high aspect ratio nanomaterials.

Ultrasonic cavitation processing (USP) is a versatile technique that has gained a lot of momentum in the last decade as a sustainable, environmentally friendly, and cost-effective process. USP uses high-frequency sound to form bubbles that expand, contract, and eventually collapse, generating high-speed liquid jets, powerful shockwaves, and acoustic streaming effects. Despite its widespread application, use of USP remains mostly empirical. For processes involving the synthesis and production of materials, harnessing the power of cavitation requires an understanding of the fundamental mechanisms driving USP. In this presentation, we record recent studies to analyse, optimise, and control USP for applications related to grain refinement of aluminium alloys, exfoliation of 2D nanomaterials, and processing of composites. High-speed cameras and in situ synchrotron imaging were used to visualise cavitation dynamics, coupled with state-of-the-art hydrophones to detect acoustic waves and shockwave emissions. Results show that optimised USP with the help of advanced modelling significantly improves grain refinement of aluminium alloys in processes such as direct-chill (DC) casting, where shockwaves are primarily responsible for the fragmentation of intermetallic crystals/dendrites. Furthermore, shockwaves act as the main driving mechanism for the exfoliation of 2Ds while cavitation activity enhances fibre dispersion in highly viscous polymers, improving matrix stability and strength.

A key technique for controlling solidification microstructures is magneto-hydrodynamics (MHD), resulting from imposing a magnetic field to solidifying metals and alloys. Applications range from bulk stirring to flow control and turbulence damping via the induced Lorentz force. Over the past two decades the Lorentz force caused by the interaction of thermoelectric currents and a magnetic field, a MHD phenomenon known as Thermoelectric Magnetohydrodynamics (TEMHD), was also shown to drive inter-dendritic flow altering microstructural evolution. In this contribution, high-speed synchrotron X-ray tomography and high-performance computational simulation are coupled to reveal the evolution, dynamics and mechanisms of solidification within a magnetic field, resolving the complex interplay and competing flow effects arising from Lorentz forces of different origins. The study enabled us to reveal the mechanisms disrupting the traditional columnar dendritic solidification microstructure, ranging from an Archimedes screw-like structure, to one with a highly refined dendritic primary array. We also demonstrate that alloy composition can be tailored to increase or decrease the influence of MHD depending on the Seebeck coefficient and relative density of the primary phase and interdendritic liquid. This work paves the way towards novel computational and experimental methods of exploiting and optimising the application of MHD in solidification processes, together with the calculated design of novel alloys that utilise these forces.

2020 The Author(s). This work focuses on ultrasonic melt treatment (UST) in a launder upon pilotscale direct chill (DC) casting of 152-mm-diameter billets from an AA6XXX alloy with Zr addition. Two casting temperatures (650 C and 665 C) were used to assess their effect on the resulting microstructure (grain size, particle size, and number density). Structure refinement results show the feasibility of UST in the DC casting launder. This is quantified through the corresponding reduction of grain size by around 50% in the billet center, or more towards the billet surface, reduction of the average Al3Zr particle size, and increase in the particle number density. A higher Al3Zr particle density was obtained when the alloy was cast at 665 C. Numerical simulation results and suggestions on how to improve the treatment quality of UST in DC casting launder are also provided. EPSRC (UK) projects UltraMelt2 (EP/R011001/1, EP/R011044/1,and EP/R011095/1).

In this article, moment‐based boundary conditions for the lattice Boltzmann method are extended to three dimensions. Boundary conditions for velocity and pressure are explicitly derived for straight on‐grid boundaries for the D3Q19 lattice. The method is compared against the bounce‐back scheme using both single and two relaxation time collision schemes. The method is verified using classical benchmark test cases. The results show very good agreement with the data found in the literature. It is confirmed from the results that the derived moment‐based boundary scheme is of second‐order accuracy in grid spacing and does not produce numerical slip, and therefore offers a transparent way of accurately prescribing velocity and pressure boundaries that are aligned with grid points in three‐dimensional.

Graphical abstract, Highlights • High-speed imaging captured de-agglomeration and dispersion of oxide aggregates. • De-agglomeration occurred from both bulk and surface of the aggregate. • Floating microbubble cluster drones produced fine suspension of loose agglomerates. • Ultrasonic capillary effect promoted de-agglomeration of particles from within. • Subharmonic and low order ultra-harmonic bubble emissions induced oxide breakage., Ultrasonic de-agglomeration and dispersion of oxides is important for a range of applications. In particular, in liquid metal, this is one of the ways to produce metal-matrix composites reinforced with micron and nano sized particles. The associated mechanism through which the de-agglomeration occurs has, however, only been conceptualized theoretically and not yet been validated with experimental observations. In this paper, the influence of ultrasonic cavitation on SiO2 and MgO agglomerates (commonly found in lightweight alloys as reinforcements) with individual particle sizes ranging between 0.5 and 10 μm was observed for the first time in-situ using high-speed imaging. Owing to the opacity of liquid metals, a de-agglomeration imaging experiment was carried out in de-ionised water with sequences captured at frame rates up to 50 kfps. In-situ observations were further accompanied by synchronised acoustic measurements using an advanced calibrated cavitometer, to reveal the effect of pressure amplitude arising from oscillating microbubbles on oxide de-agglomeration. Results showed that ultrasound-induced microbubble clusters pulsating chaotically, were predominantly responsible for the breakage and dispersion of oxide agglomerates. Such oscillating cavitation clusters were seen to capture the floating agglomerates resulting in their immediate disintegration. De-agglomeration of oxides occurred from both the surface and within the bulk of the aggregate. Microbubble clusters oscillating with associated emission frequencies at the subharmonic, 1st harmonic and low order ultra-harmonics of the driving frequency were deemed responsible for the breakage of the agglomerates.

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.

Magnetohydrodynamic flows can be driven by Lorentz forces acting on thermoelectric currents. Their effects on tip velocities of Pd dendrites solidifying from an undercooled melt under magnetic field intensities of up to 6 T were investigated by in-situ observations using a high-speed camera. At low undercoolings, the tip velocities are depressed by magnetic fields of low and high intensities, but recover under an intermediate magnetic field intensity. At high undercoolings, the tip velocities are also depressed, but their recovery is shifted to a higher magnetic field intensity. These observations on Pd dendrites support and extend the findings obtained in previous studies on Ni and Fe dendrites, and fully verify the convection effects on dendritic growth due to three thermoelectric magnetohydrodynamic flow patterns as predicted in recent numerical simulations.

© The Author(s), 2021. The application of cavitation-induced shock waves generated at low driving frequencies, known as power ultrasound, is essential for a wide range of fields, such as sonochemistry, lithotripsy, nanomaterials, emulsions and casting, to name but a few. In this paper, we present measurements of the shock wave pressures emitted by cavitating bubbles in water, under ultrasonic excitation produced by an immersed probe oscillating at 24 kHz. A broad-spectrum fibre-optic hydrophone calibrated in the range of 1–30 MHz was used for this purpose. Spectral analysis of the data reveals a consistent resonance peak at a very narrow range of frequencies (3.27–3.43 MHz). Results were confirmed using real-time analysis of high-speed recordings. By eliminating other possible sources, we propose that this new peak might be associated with shock wave emissions from collapsing bubbles. Spatial maps obtained by collating individual shock wave pressures highlight the effect of pressure shielding with increasing input power, attributed to a cloud of bubbles surrounding the probe. This work contributes towards the elucidation of the key properties of cavitation-driven shock waves and the underlying mechanisms, essential in controlling the effectiveness of the external processing conditions on various physical, chemical and biological systems. UK Engineering and Physical Sciences Research Council (EPSRC) through the UltraMelt2 (grants EP/R011001/1, EP/R011095/1 and EP/R011044/1) and EcoUltra2D (grants EP/R031401/1, EP/R031665/1, EP/R031819/1 and EP/R031975/1) projects.

This work focuses on the effects of ultrasonic melt treatment (UST) during direct-chill (DC) casting on the temperature distribution across the billet, sump profile, and the resulting microstructure. Two AA6008 billets were cast; one was treated with UST in the hot top while the other was not. To determine the temperature distribution along the billet, multi-point temperature measurements were made across the radii of both billets. The sump profile was also analyzed through macrostructure analysis, after Zn was poured into the sump, while structure refinement was quantified through grain-size measurements. A numerical model of ultrasound-assisted DC casting is validated using the temperature measurements. As an outcome, this study provides information on the extent to which UST affects the sump profile and the corresponding changes in the microstructure. The knowledge gained from this study paves the way towards optimization of UST parameters in DC casting.

The effects of applying a 0.2-T transverse magnetic field on a solidifying Ga-25 wt%In alloy have been investigated through a joint experimental and numerical study. The magnetic field introduced significant changes to both the microstructure and the dynamics of escaping high-concentration Ga plumes. Plume migration across the interface was quantified and correlated to simulations to demonstrate that thermoelectric magnetohydrodynamics (TEMHD) is the underlying mechanism. TEMHD introduced macrosegregation within the dendritic structure, leading to the formation of a stable “chimney” channel by increasing the solutal buoyancy in the flow direction. The resulting pressure difference across the solidification front introduced a secondary hydrodynamic phenomenon that subsequently caused solute plume migration.

Contactless ultrasound is a novel, easily implemented, technique for the Ultrasonic Treatment (UST) of liquid metals. Instead of using a vibrating sonotrode probe inside the melt, which leads to contamination, we consider a high AC frequency electromagnetic coil placed close to the metal free surface. The coil induces a rapidly changing Lorentz force, which in turn excites sound waves. To reach the necessary pressure amplitude for cavitation with the minimum electrical energy use, it was found necessary to achieve acoustic resonance in the liquid volume, by finely tuning the coil AC supply frequency. The appearance of cavitation was then detected experimentally with an externally placed ultrasonic microphone and confirmed by the reduction in grain size of the solidified metal. To predict the appearance of various resonant modes numerically, the exact dimensions of the melt volume, the holding crucible, surrounding structures and their sound properties are required. As cavitation progresses the speed of sound in the melt changes, which in practice means resonance becomes intermittent. Given the complexity of the situation, two competing numerical models are used to compute the soundfield. A high order time-domain method focusing on a particular forcing frequency and a Helmholtz frequency domain method scanning the full frequency range of the power supply. A good agreement is achieved between the two methods and experiments which means the optimal setup for the process can be predicted with some accuracy.

Melt pools formed in laser additive manufacturing (AM) are subject to large thermal gradients, resulting in the formation of thermoelectric currents due to the Seebeck effect. When in the presence of an external magnetic field, a Lorentz force is formed which drives fluid flow in the melt pool. This Thermoelectric Magnetohydrodynamics (TEMHD) phenomenon, can have a significant impact on the melt pool morphology and can alter the microstructural evolution of the solidification process. By coupling steady-state mesoscopic melt pool calculations to a microscopic solidification model, predictions of the resulting microstructure for multiple deposited layers have been obtained. The results indicate that the magnetic field can have a transformative effect on the microstructure and solute redistribution. This study highlights the theoretical potential for using magnetic fields as an additional control system to tailor AM microstructures.

Large thermal gradients in the melt pool from rapid heating followed by rapid cooling in metal additive manufacturing generate large thermoelectric currents. Applying an external magnetic field to the process introduces fluid flow through thermoelectric magnetohydrodynamics. Convective transport of heat and mass can then modify the melt pool dynamics and alter microstructural evolution. As a novel technique, this shows great promise in controlling the process to improve quality and mitigate defect formation. However, there is very little knowledge within the scientific community on the fundamental principles of this physical phenomenon to support practical implementation. To address this multi-physics problem that couples the key phenomena of melting/solidification, electromagnetism, hydrodynamics, heat and mass transport, the lattice Boltzmann method for fluid dynamics was combined with a purpose-built code addressing solidification modelling and electromagnetics. The theoretical study presented here investigates the hydrodynamic mechanisms introduced by the magnetic field. The resulting steady-state solutions of modified melt pool shapes and thermal fields are then used to predict the microstructure evolution using a cellular automata-based grain growth model. The results clearly demonstrate that the hydrodynamic mechanisms and, therefore, microstructure characteristics are strongly dependent on magnetic field orientation. This article is part of the theme issue ‘Patterns in soft and biological matters'.

Purpose The purpose of this paper is to investigate a new type of nozzle which is free from erosion and non-contaminating the outflow metal. Cold crucible melting technique with electromagnetic induction is used to obtain reactive metal castings and produce high-quality metal powders for aerospace, automotive and medical applications. An important part of this technology is the nozzle used to pour the molten alloy through the bottom opening. Design/methodology/approach The paper uses mathematical modeling technique, previously validated on multiple similar cases, to investigate a new type of nonconsumable nozzle made of copper segments. Findings The design of the nozzle requires to satisfy the narrow balance between the thin solidified protective layer on the wall while avoiding the blockage of the outflow if the nozzle is frozen completely. The sensitivity of the outflow to the nozzle diameter is investigated. The AC electromagnetic force leads to high mixing rates, transitional flow structures and turbulence of the melt, contributing to the melt shape dynamics and the heat loss to walls. Originality/value The beneficial features of the cold crucible melting to purify the melt from particulate contamination are explained using the full melting and pouring cycle.

The current challenge for upscaling the ultrasonic melt processing (USP) technology to industrial scale is in improving the treatment efficiency using a single-sonotrode setup. To achieve this, we suggest two innovative approaches: increasing the melt residence time and exploiting acoustic resonance. This can be achieved through flow management in a launder by partitions where the resonance length within the partitions is equal or at integer steps to the wavelength of the incident sound wave. This study focuses on acoustic pressure measurements at different partition configurations and flow conditions combined with numerical modelling of the process. The measurements are done both in liquid aluminum and in water as its transparent analogue. The acoustic pressure measurements are then used to assess melt treatment improvement through cavitation activity and pressure distribution in the launder as well as to verify and further develop the numerical model.

Graphical abstract, Highlights • Mechanical properties of extracted intermetallics determined using a nano-indenter. • High speed imaging captures shock waves breaking intermetallics. • Shock waves seen to promote crack growth leading to fragmentation. • In-situ shock wave pressure measurements obtained using a fibre optic hydrophone. • Subharmonic emissions generate repetitive bending and fracture of intermetallics., One of the main applications of ultrasonic melt treatment is the grain refinement of aluminium alloys. Among several suggested mechanisms, the fragmentation of primary intermetallics by acoustic cavitation is regarded as very efficient. However, the physical process causing this fragmentation has received little attention and is not yet well understood. In this study, we evaluate the mechanical properties of primary Al3Zr intermetallics by nano-indentation experiments and correlate those with in-situ high-speed imaging (of up to 1 Mfps) of their fragmentation process by laser-induced cavitation (single bubble) and by acoustic cavitation (cloud of bubbles) in water. Intermetallic crystals were chemically extracted from an Al-3 wt% Zr alloy matrix. Mechanical properties such as hardness, elastic modulus and fracture toughness of the extracted intermetallics were determined using a geometrically fixed Berkovich nano-diamond and cube corner indenter, under ambient temperature conditions. The studied crystals were then exposed to the two cavitation conditions mentioned. Results demonstrated for the first time that the governing fragmentation mechanism of the studied intermetallics was due to the emitted shock waves from the collapsing bubbles. The fragmentation caused by a single bubble collapse was found to be almost instantaneous. On the other hand, sono-fragmentation studies revealed that the intermetallic crystal initially underwent low cycle fatigue loading, followed by catastrophic brittle failure due to propagating shock waves. The observed fragmentation mechanism was supported by fracture mechanics and pressure measurements using a calibrated fibre optic hydrophone. Results showed that the acoustic pressures produced from shock wave emissions in the case of a single bubble collapse, and responsible for instantaneous fragmentation of the intermetallics, were in the range of 20–40 MPa. Whereas, the shock pressure generated from the acoustic cavitation cloud collapses surged up to 1.6 MPa inducing fatigue stresses within the crystal leading to eventual fragmentation.

© The Authors, 2020. Ultrasonic cavitation melt treatment (UST) of aluminium alloys has received considerable attention in the metal industry due to its simple and effective processing response. The refined primary intermetallic phases formed in the treated alloys during controlled solidification, govern alloy structural and mechanical properties for applications in the automotive and aerospace industries. Since the UST is performed close to the liquidus temperatures of the alloys, understanding the refinement mechanism of the primary intermetallic phases has been beset by difficulties in imaging and handling of liquid metals. In this paper, the sonofragmentation behaviour of primary intermetallic Al3Zr crystals extracted from the matrix of an Al-3 wt% Zr alloy and fixed on a solid substrate was investigated. The intermetallics were exposed to cavitation action in deionized water at 24 kHz of ultrasound frequency. The fragmentation mechanism from the nearby collapsing cavitation bubbles was studied with in-situ high speed imaging. Results revealed that the main fragmentation mechanism is associated with the propagation of shock wave emissions from the collapsing bubble clouds in the vicinity of the crystal. The mechanical properties of the Al3Zr phase determined previously were used for the fracture analysis. It was found that an Al3Zr intermetallic undergoes low cycle fatigue fracture due to the continuous interaction with the shock wave pressure. The magnitude of the resulting shear stress that leads to intermetallic fragmentation was found to be in the range of 0.6 – 1 MPa.

The aim of this paper is to develop a stability theory and a numerical model for three density-stratified electrically conductive liquid layers. Using regular perturbation methods to reduce the full three-dimensional problem to the shallow layer model, the coupled wave and electric current equations are derived. The problem set-up allows for weakly nonlinear velocity field action and an arbitrary vertical magnetic field. Further linearisation of the coupled equations is used for the linear stability analysis in the case of a uniform vertical magnetic field. New analytical stability criteria accounting for the viscous damping are derived for particular cases of practical interest and compared to the numerical solutions for a variety of materials used in batteries. These new criteria are equally applicable to the aluminium electrolysis cell magnetohydrodynamic (MHD) stability estimates.

A high frequency tuned electromagnetic induction coil is used to induce ultrasonic pressure waves leading to cavitation in alloy melts. This presents an alternative &lsquo, contactless&rsquo, 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&ndash, 5Ti&ndash, 1B grain refiner.

The prediction of the acoustic pressure field and associated streaming is of paramount importance to ultrasonic melt processing. Hence, the last decade has witnessed the emergence of various numerical models for predicting acoustic pressures and velocity fields in liquid metals subject to ultrasonic excitation at large amplitudes. This paper summarizes recent research, arguably the state of the art, and suggests best practice guidelines in acoustic cavitation modelling as applied to aluminium melts. We also present the remaining challenges that are to be addressed to pave the way for a reliable and complete working numerical package that can assist in scaling up this promising technology. Engineering and Physical Sciences Research Council (EPSRC), UK

Ultrasonic processing (USP) during direct-chill (DC) casting of light metal alloys is typically applied in the sump of a billet. This approach, though successful for structure refinement and modification, has two main drawbacks: (a) mixture of mechanisms that rely heavily on dendrite fragmentation and (b) a limited volume that can be processed by a single ultrasonic source. We suggest moving the location of USP from the sump to the launder and applying it to the melt flow for continuous treatment. The apparent benefits include: (a) degassing of the melt volume, (b) grain refinement through activation of non-metallic inclusions, fragmentation of primary crystals, and deagglomeration of grain refining substrates, and (c) a possibility to use a single ultrasonic source for processing large melt volumes. To optimize this process with regard to the acoustic intensity and melt residence time in the active cavitation zone, flow modification with baffles as well as informed location of the ultrasonic source are required. In this paper, we demonstrate the results of experimental trials where the degassing degree and grain refinement have been the indicators of the USP efficiency for two aluminium alloys, i.e. LM25 and AA7050. The results are supported by acoustic measurements and computer simulations.

Fe contamination is a serious composition barrier for Al recycling. In Fe-containing Al-Si-Cu alloy, a brittle and plate-shaped β phase forms, degrading the mechanical properties. Here, 4D (3D plus time) synchrotron X-ray tomography was used to observe the directional solidification of Fe-containing Al-Si-Cu alloy. The quantification of the coupled growth of the primary and β phase via machine learning and particle tracking, demonstrates that the final size of the β intermetallics were strongly influenced by the solute segregation and space available for growth whereas the β orientation was controlled by the temperature gradient direction. The work can be used to validate predictive models.

Contactless ultrasound uses Lorentz forces from a secondary coil to induce ultrasonic vibrations in alloy melts. To achieve pressures high enough for cavitation, resonance is required. However, the prediction of the resonant modes for a melt in a crucible is complex, due to the transmission and reflection of sound within the crucible walls. Two acoustic models, one solving a simplified momentum equation in the time domain, the other solving the Helmholtz equation in the frequency domain are compared. The frequency domain model allows a fast sweep of frequencies for resonance tuning, and the transient model enables a more detailed analysis. Validation is against analytic test cases derived with boundary conditions specific for the liquid metal medium and against experimental data obtained in an aluminum melting crucible. Results confirm that sound transmission into the crucible walls has a significant effect on resonant frequencies and needs to be accounted for.

Ultrasonic pressure waves generated using a tuned electromagnetic induction coil promote cavitation in alloy melts as an alternative to the immersed sonotrode technique. The method targets the same benefits offered by traditional UST (degassing, microstructure refinement, dispersion of particles), but without some of its drawbacks. The method is contactless, meaning it can be applied equally to high temperature/reactive melts, avoiding contamination due to probe erosion, and consequently, it is maintenance free. Due to induction stirring, larger volumes of melt can be treated (a major limitation of the traditional method), as the liquid is forced to pass repeatedly through zones of cavitation activity. The coil configuration used will depend on application. In the installation shown, a top conical coil immersed in aluminium melt (contactless due to EM repulsion) was used. Simulations of sound, flow and EM fields are given, compared with experiments and indicating strong stirring, evidence of cavitation through emitted sound signals and, most importantly, grain refinement.

The quantification of acoustic pressures in liquid metals is of paramount interest for the optimization of ultrasonic melt treatment (UST) of large volumes. Until recently, the measurements of acoustic pressure and cavitation intensity in a melt were cumbersome and unreliable due to the high temperatures and the lack of suitable instruments. These difficulties imposed strict limitations on the experimental and numerical investigation of cavitation and bubble dynamics within liquid metals. In recent years, our group used a unique calibrated high temperature cavitometer to measure cavitation activity and acoustic pressures in liquid aluminum. Phenomena such as acoustic attenuation, shielding, and cavitation intensity have been studied. These measurements were also used to validate a non-linear acoustic numerical model applicable to flow in bubbly liquids subject to acoustic cavitation. Both experimental and numerical characterization of the acoustic and flow fields provides a powerful tool to optimize cavitation processing in liquid metals.

Acoustic streaming and its attendant effects in the sump of a direct-chill (DC) casting process are successfully predicted under ultrasonic treatment for the first time. The proposed numerical model couples acoustic cavitation, fluid flow, heat and species transfer, and solidification to predict the flow pattern, acoustic pressure, and temperature fields in the sump. The model is numerically stable with time steps of the order of 0.01 s and therefore computationally attractive for optimization studies necessitating simulation times of the order of a minute. The sump profile is altered by acoustic streaming, with the slurry region depressed along the centreline of the billet by a strong central jet. The temperature gradient in the transition zone is increased, potentially interfering with grain refinement. The cooling rate in the sump is also altered, thereby modifying the dendrite arm spacing of the as-cast billet. The relative position of the sonotrode affects the sump profile, with the sump depth decreased by around 5 mm when the sonotrode is moved above the graphite ring level by 100 mm. The acoustic streaming jet penetrates into the slurry zone and, as a result, the growth direction of dendritic grains in the off-centre position is altered.

A high frequency tuned electromagnetic (EM) induction coil can be used to induce ultrasonic pressure waves leading to gas cavitation in alloy melts. This is a useful ‘contactless’ approach compared to the usual immersed sonotrode technique. One then expects the same benefits obtained in the traditional ultrasonic treatment (UST) of melts, such as degassing, microstructure refinement and dispersion of particles. However, such an approach avoids melt contamination due to probe erosion prevalent in immersed sonotrodes and it has the potential to be used on higher temperature and reactive alloys. Induction stirring due to the Lorentz force produced by the coil is an added benefit, allowing for the treatment of large melt volumes, a current limitation of UST systems. At ultrasonic frequencies (> 20 kHz), due to the ‘skin effect’ electromagnetic forces vibrate just a thin volume by the surface of the metal facing the induction source. These vibrations are transmitted as acoustic pressure waves into the bulk and to achieve sufficient fluctuation amplitudes for cavitation, acoustic resonance is sought by carefully adjusting the generator frequency. This is akin to the tuning of a musical instrument, where the geometry and sound properties of the metal, crucible and surrounding structure play an important part. In terms of modelling, this is a multi-physics system, since fluid flow with heat transfer and phase change are coupled to electromagnetic and acoustic fields. The various models used and their coupling are explained in this paper, together with the various complications arising by the physics of cavitation. Experimental validation is obtained on a prototype rig featuring a conical induction coil inserted into the melting crucible containing the various alloys being examined. When resonance is reached, measurements demonstrate strong stirring, evidence of cavitation and finally grain refinement.

In situ structural mechanics are an often neglected area when modelling alloy microstructure during solidification, despite the existence of practical examples and studies which seem to indicate that the interaction between thermal or mechanical stresses and microstructure can have a significant impact on its evolution and hence the final properties at a macroscopic level. A bespoke structural mechanics solver using the finite volume method has been developed to solve the linear elasticity equations, with design choices being made to facilitate the coupling of this solver to run in situ with an existing solidification model. The accuracy of the structural mechanics solver is verified against an analytic solution and initial results from a fully coupled system are presented which demonstrate in a fundamental example that the interaction between structural mechanics and a solidifying dendrite can lead to a significant change in growth behaviour.

In the undercooled solidification of pure metals, the dendrite tip velocity has been shown experimentally to have a strong dependence on the intensity of an external magnetic field, exhibiting several maxima and minima. In the experiments conducted in China, the undercooled solidification dynamics of pure Ni was studied using the glass fluxing method. Visual recordings of the progress of solidification are compared at different static fields up to 6 T. The introduction of microscopic convective transport through thermoelectric magnetohydrodynamics is a promising explanation for the observed changes of tip velocities. To address this problem, a purpose-built numerical code was used to solve the coupled equations representing the magnetohydrodynamic, thermal and solidification mechanisms. The underlying phenomena can be attributed to two competing flow fields, which were generated by orthogonal components of the magnetic field, parallel and transverse to the direction of growth. Their effects are either intensified or damped out with increasing magnetic field intensity, leading to the observed behaviour of the tip velocity. The results obtained reflect well the experimental findings. This article is part of the theme issue ‘From atomistic interfaces to dendritic patterns’.

Magnetohydrodynamics (MHD) is the scientific field devoted to studying the interaction between electric or magnetic fields and fluid flow in electrically conducting liquids. MHD phenomena appear in a wide range of metal processing applications, either as an unintended consequence of the presence of electric currents during processing or by the deliberate application of external magnetic fields or currents to a process. The allied field of Electromagnetic Processing of Materials (EPM) has many applications, ranging from melting, flow control, melt cleaning, stirring, arc processes (welding, AM, vacuum arc remelting) and electrolytic processes, including recently the field of liquid metal batteries for renewable energy storage. In terms of modeling and simulation, EPM remains a difficult task to master, since in addition to the usual flow, heat transfer, and solidification, one has to address the coupled electric and magnetic fields, often in a dynamic fashion. In this chapter, we divide applications in terms of applied current type, i.e. DC (aluminum electrolysis, vacuum arc remelting) or AC (EM levitation, induction crucibles, PV silicon kerf recycling and the contactless ultrasonic vibration of melts).

In an attempt to quantify the instantaneous pressure field in cavitating liquids at large forcing signals, pressures were measured in four different liquids contained in vessels with a frequency mode in resonance with the forcing signal. The pressure field in liquid metal was quantified for the first time, with maximum pressures of the order of 10-15 MPa measured in liquid aluminium. These high pressures are presumed to be responsible for deagglomeration and fragmentation of dendritic intermetallics and other inclusions. Numerical modelling showed that acoustic shielding attenuates pressure far from the sonotrode and it is prominent in the transparent liquids studied but less so in aluminium, suggesting that aluminium behaviour is different. Due to acoustic shielding, the numerical model presented cannot adequately capture the pressure field away from the intense cavitation zone, but gives a good qualitative description of the cavitation activity. The results obtained contribute to understanding the process of ultrasonic melt treatment (UST) of metal alloys, while facilitating further the guidelines formulation and reproducible protocols for controlling UST at industrial levels.

The aerospace and automotive industries are seeking advanced materials with low weight yet high strength and durability. Aluminum and magnesium-based metal matrix composites with ceramic micro- and nano-reinforcements promise the desirable properties. However, larger surface-area-to-volume ratio in micro- and especially nanoparticles gives rise to van der Waals and adhesion forces that cause the particles to agglomerate in clusters. Such clusters lead to adverse effects on final properties, no longer acting as dislocation anchors but instead becoming defects. Also, agglomeration causes the particle distribution to become uneven, leading to inconsistent properties. To break up clusters, ultrasonic processing may be used via an immersed sonotrode, or alternatively via electromagnetic vibration. This paper combines a fundamental study of acoustic cavitation in liquid aluminum with a study of the interaction forces causing particles to agglomerate, as well as mechanisms of cluster breakup. A non-linear acoustic cavitation model utilizing pressure waves produced by an immersed horn is presented, and then applied to cavitation in liquid aluminum. Physical quantities related to fluid flow and quantities specific to the cavitation solver are passed to a discrete element method particles model. The coupled system is then used for a detailed study of clusters’ breakup by cavitation.

A new method is presented for numerically solving the equations of electromagnetic induction in conducting materials using native, primary variables and not a magnetic vector potential. Solving for the components of the electric field allows the meshed domain to cover only the processed material rather than extend further out in space. Together with the finite volume discretisation this makes possible the seamless coupling of the electromagnetic solver within a multi-physics simulation framework. After validation for cases with known results, a 3-dimensional industrial application example of induction heating shows the suitability of the method for practical engineering calculations.

Aluminum- and magnesium-based metal matrix nano-composites with ceramic nano-reinforcements promise low weight with high durability and superior strength, desirable properties in aerospace, automobile, and other applications. However, nano-particle agglomerations lead to adverse effects on final properties: large-size clusters no longer act as dislocation anchors, but instead become defects; the resulting particle distribution will be uneven, leading to inconsistent properties. To prevent agglomeration and to break-up clusters, ultrasonic processing is used via an immersed sonotrode, or alternatively via electromagnetic vibration. A study of the interaction forces holding the nano-particles together shows that the choice of adhesion model significantly affects estimates of break-up force and that simple Stokes drag due to stirring is insufficient to break-up the clusters. The complex interaction of flow and co-joint particles under a high frequency external field (ultrasonic, electromagnetic) is addressed in detail using a discrete-element method code to demonstrate the effect of these fields on de-agglomeration.