Ultrasonic Modification of Aluminum Surfaces: Comparison between Thermal and Ultrasonic Effects.

Ultrasound has become an increasingly popular tool in the modification of metal surfaces, imbuing them with various desired characteristics and functionalities. The exact role played by ultrasound in such processes remains largely speculative and thus requires clarification. In this study, aluminum was taken as a model metal to probe the nature of the surface modification, focusing on both chemical and physical changes. Using metal plates as substrates, the formation of a characteristic porous surface structure was ascertained to arise from a purely thermal mechanism, with the ultrasound providing an inhibitory influence when compared with controlled experiments matching the thermal conditions of sonication. No beneficial effect was observed through sonication, with regards to surface texture, porosity, and electrochemistry. However, for metal powders, a pronounced change in the phase composition was observed following ultrasonic exposure, largely attributed to the growth of bayerite from the surface. The immobilization of the powder on a thin epoxy film nullified such effects. This suggests that the changes in phase composition are due to the effect of ultrasound-induced mechanical stirring and high speed particle motion on the dissolution and reprecipitation of the metal oxide and hydrated oxide species. This work is of significant value to researchers both in materials science and in sonochemistry.