CHAPTER 1

INTRODUCTION
What does this chapter about?
1.1 Problem Summary and Introduction
This chapter includes the introduction to Metal Matrix Composites (MMC) and various method
of fabricating. Especially Ultrasonic Treatment of melt is briefly introduced.

1.1.1 Introduction to Metal Matrix Composites (MMC)

With the advancement of the technology, demand for materials with light weight, high strength,
and having good tribological properties is ever increasing. Industries in automobile, aerospace,
defence and other sector are in constant need for material with good strength, toughness even
at the elevated temperature which conventional material fail to provide as a combination of all
the required properties. Thus, to fulfil the demand from the emerging trends, materials named
“composite” were developed. Composite are material made from two or more constituent
materials with significantly different physical or chemical properties, that when combined,
produce a material with characteristics different from the individual components. Composite
materials are composed of reinforcement embedded in a matrix (polymers) (Surappa et al.,
2003). Metal matrix composites (MMCs) are under consideration as potential candidate
materials for a variety of structural application in aerospace, transportation, defence and sport
industries because the of range of mechanical properties they possess (Hashin et al., 2002).

Metal matrix composite refers to composite system which is based on metal or alloy substrate,
combined with metallic or non-metallic reinforcements. The aim of designing metal matrix
composite materials is to combine the desirable attributes of metal and ceramics. The addition
of high strength, high modulus refractory particles to a ductile metal matrix will produce a
material whose mechanical properties are intermediate between the matrix alloy and the
ceramic reinforcement. The matrix is usually an alloy, and the reinforcements are usually a
ceramic. Metal matrix composite combines metallic properties of matrix alloys (ductility and
toughness) with ceramic properties of reinforcements (high strength and high modulus), leading
to greater strength in shear and compression and higher service-temperature capabilities
(Rajamuthamil et al., 2013).
In the composite production the matrix act as the bonding element and its function is to transfer
and distribute the load to reinforced material evenly. Hence there should be strong bonding
between matrix and reinforcement. Metal matrix composite withstands stresses by the transfer
and distribution of an applied load from the ductile matrix to the reinforcement material. This
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load transfer is only possible due to the existence of an interfacial bond between the
reinforcement elements and the matrix material. Thus properties of composites are strongly
dependent on the properties of their constituent materials, their distribution and the interaction
among. Thus, the appropriate selection of reinforcement material and its properties coupled
with a good fabrication method affects bonding and will significantly influence the resulting
metal matrix composite. Systematic design and synthesis procedure allow unique combination
of engineering properties in composite like high elevated temperature strength, fatigue strength,
damping prop MMCs provide flexibility in terms of properties required. The correct selection
of reinforcement type, size is important in order to obtain the best combination of properties at
substantially low cost. Several criteria for the selection of matrix and reinforcement materials
are as follows: (Hashim et al., 1999).
1) Compatibility

2) Thermal properties

3) Fabrication method

4) Application
Metal Metrix Composite are composed of a metallic matrix (aluminium, magnesium, iron,
cobalt, copper) and a dispersed ceramic (oxide, carbides) or metallic (lead, tungsten,
molybdenum) phase. Silicon Carbide (SiC) is composed of carbon and silicon atoms in
tetrahedral arrangement with strong bonds in the crystal lattice. This produces a very hard and
strong material. Introduction of SiC to the aluminium matrix substantially enhances the
strength, the modulus, the abrasive wear resistance and thermal stability. SiC is easily available
and has good wettability with aluminium alloys. (Idrisi et al., 2014).
1.1.2 Fabrication Methods
Fabrication method for the metal matrix composite can be classified in to two groups: liquid
state processing and solid state processing.
Squeeze Casting is a liquid state processing, where reinforcement are preheated which are
placed into a preheated die, filling the die with molten matrix metal, squeezing the molten metal
into the preform using a hydraulic press with a preheated ram, holding the pressure during
solidification, releasing the pressure and ejecting the resulting composite. The preheated
reinforcement, usually in the form of a pre-compacted and inorganically bonded preform, is
placed in a preheated metal die. Superheated liquid metal is introduced into the die and pressure
is applied to drive the metal into the interstices between the reinforcing materials. The pressure
required combining matrix and the reinforcement is a function of the friction effects due to
viscosity of the molten matrix as it fills the ceramic perform. Squeeze casting produces
components, free from gas or shrinkage porosity. This process can be used for large scale
2
manufacturing but has some limitation like it requires careful control of the process variables,
including the liquid metal, reinforcement preheat temperature, the metal alloying elements,
external cooling, the melt quality, the tooling temperature, the time lag between die closure and
pressurization, the pressure levels and duration and the plunger speed. Imperfect control of
these process variables results in various defects, including freeze chocking, preform
deformation, oxide inclusions and other common casting defects.
Powder Metallurgy is a solid state processing method where matrix material, reinforcement
particles both are made in powder form which are mixed together with the binders and are fed
into the mold to get desired shape. Next step is the application of pressure which presses the
powder known as cold pressing method. In order to facilitate the bonding between the powder
particles, the compact is then heated to a temperature Chapter1 Introduction that is below the
melting point but sufficiently high to develop significant solid-state diffusion (sintering).
Powder Metallurgy is popular because it is reliable compared with other alternative methods,
but it has also some demerits. The blending step is a time consuming, expensive and potentially
dangerous operation. In addition, it is difficult to achieve an even distribution of particulate
throughout the product and the use of powders requires a high level of cleanliness, otherwise
inclusions will be incorporated into the product with a deleterious effect on fracture toughness,
fatigue life. Moreover, there is difficulty in removing binders which is used to hold the particles
together.
1.1.3 Stir Casting
The stir casting method is commonly used method for mixing reinforcement into molten matrix
material to produce composite materials. These is the simplest and most commercially used
techniques also known as vortex matrix. The process is simple, flexible, used for large quantity
production and economical. (Muley et al., 2014).

Stir Casting process are further classified in to three types namely,

1) Mechanically Stirring

2) Electromagnetic Stirring

3) Ultrasonic Stirring
Introduction to Ultrasonic Stirring Technology (UST):
The main objective of this study is to determine the dominant mechanism for UST grain
refinement and the key parameter of the UST experiments. UST can apply high intensity of
acoustic energy into the melt During cavitation, low pressure create tiny bubble while high
pressure makes the bubble collapse produce shock waves .It is believed that shock waves
occurring near the solidification front cause dendrite fragmentation. During the Solidification
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of casting, UST can be used for degassing and microstructure refinement and modification (Jia
et al., 2013).
1.2 Aim and objectives of the project
 Selection of process parameter for ultrasonic treatment.
 Analysis of ultrasonic treatment in Water
 Analysis of ultrasonic treatment in Diethyl Ether
 Analysis of ultrasonic treatment in Ethanol
 Analysis of ultrasonic treatment in Ethylene Glycol
 Analysis of ultrasonic treatment in Glycerol
 Analysis of ultrasonic treatment in Toluene
1.3 Problem Specifications
1.4 Brief literature review and Prior Art Search (PAS) about the project.
The literature review has been carried out on Metal Matrix Composites made by ultrasonic
stirring technology.

Jia S. (2013) studied the effect of ultrasonic treatment on the microstructure and mechanical
properties of A356 alloy. He compared the ultrasonic treatment & non-ultrasonic treatment and
concluded that, the samples without ultrasonic treatment have coarser microstructures than the
ones with ultrasonic treatment.

Idrisi and Deva (2014) studied the behaviour of aluminium 5083 with SiC as reinforcement
produced by stir casting method and ultrasonic assisted stir casting method. They employed the
hardness and density tests to obtain the mechanical properties of specimens by adding different
percentages if SiC and trend were compared between the samples developed by stir casting
method and ultrasonic assisted stir casting method. He concluded that, in stir casting processing
method the mechanical properties increased by increasing weight % of SiC and also with
ultrasonic assisted stir casting method.

Bhojak et al. (2015) used ultrasonic technology over existing technology to compare the
results of conventional degasser units available in the market. The setup consists of 20 KHz
frequency and 2 KW power. The hardness found is 65 Rockwell in conventionally treated
aluminium alloy while the hardness found is 66 to 81 Rockwell in ultrasonically treated
aluminium alloy. It clearly indicates 24.61% improvement in material’s hardness quality.

Su Hai et al. (2012) prepared nano - 𝐴𝑙2 𝑂3/2024 composites by solid-liquid mixed casting
combined with ultrasonic treatment to obtain fine grain structure and homogeneous particles
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distribution in the matrix. The setup consists of 20 KHz frequency. He compared the alloy
matrix with ultrasonically treated nano- 𝐴𝑙2 𝑂3 /2024 and concluded that, the ultimate strength
and yield strength of 1 wt % nano- 𝐴𝑙2 𝑂3/2024 composites is enhanced by 37% and 81%
respectively. The improvement was due to uniform distribution of reinforcement and grain
refinement of aluminium matrix.

Muley A. (2015) investigated ultrasonic probe assisted stir casting method which gives better
distribution of nano particles to enhance the properties of composites materials. He used
combine mechanical and ultrasonic stirring technology and found that, it enhanced overall
properties of MMCs.

Atamanenko et al. (2010) summarized the results of experimental work performed on various
alloying systems at different stages of solidification. They also analysed the influence of
ultrasonic treatment parameters and solidification conditions on the final grain structure. They
found that small additions of zirconium and titanium can significantly increase the efficiency
of ultrasonic treatment.

Rana et al. (2013) fabricated AA 5083 alloy micro and nano SiC composites by ultrasonic
assisted stir casting. Different weight % of SiC particles and nano were used for synthesis of
composites. They measured the various properties of composites like tensile strength,
compressive strength, hardness, ductility and density. He concluded that tensile strength,
compressive strength and hardness increases with increases in
wt. % of SiC particles. Maximum tensile strength, compressive strength and hardness found
270 MPa, 361 MPa and 79 BHN respectively.

Mazahery and Shabani (2015) studied the microstructure of nano composites based on the
A356 aluminium alloy reinforced with nano SiC particles fabricated via stir casting. The results
showed that the nano sized SiC particles are successfully incorporated into the aluminium
matrix and the composites contain little porosity and the amount of porosity increases with
increasing volume fraction of SiC which can be attributed to the increased surface area of the
nano SiC particles. It was also observed a reasonably uniform distribution of SiC nano particles
in the Al matrix.

Prakash et al. (2015) used SiC and B4C particles as reinforcements and Al6061 as matrix to
produce a composites by stir casting process. The composites were produced by varying the
particulate addition by weight fraction of Al (90%), SiC (5%, 6.5% and 8%) and B4C (5%,
3.5% and 2%). Al rods were preheated at 850ºC for 3 to 4 hours before melting and mixing the

5
SiC and B4C particles were preheated at 840ºC for 1 to 3 hours to make their surfaces oxidized.
The furnace temperature was first raised above the liquids to melt the Al alloy completely and
was then cooled down just below the liquids to keep the slurry in a semisolid state. Manual
mixing was used because it was very difficult to mix using automatic device when the alloy
was in a semisolid state. After sufficient manual mixing was done, the composite slurry was
reheated to a fully liquid state and then automatic mechanical mixing was carried out for about
10 minutes at a normal stirring rate of 600 rpm.

Hassan et al. (2014) were developed AMMCs using AL6063 as matrix material and SiC
particles with various RVR (between 10% and 50% at 10% intervals) as reinforcement.
Composites were produced using stir casting technique and the homogeneous mixture obtained
cast into cylindrical blanks. The results indicated that the produced composites possess superior
metallurgical properties. It was also found that an increase in the quantity of SiC reinforcement
positively effects on the metallurgical properties only up to a 40%wt SiC beyond this, increased
clustering of the reinforcements.

Adat et al. (2015) manufactured a metal matrix composite by reinforcing alloy Al356 with
Al2O3 and fly ash particles with difference RVR (2, 4 and 6% each) using stir casting process.
After cleaning A356 alloy ingots, they were cut to proper sizes, weighed in requisite quantities
and charged into a cast iron crucible placed in the furnace at 400 ºC.1% pure Mg was added
into the charge at 600 ºC after confirming the semisolid state to improve wettability. Then
material was hold for about an hour until its temperature gain reached 800 ºC. The scum powder
(0.05% of Al356) was added into the melt which resulted into accumulation of impurities at the
surface of liquid melt. Then the scum was removed. Degasification tables of Hexachloroethane
(0.05% of Al356) were added for removal of gases from the molten alloy. The combination of
reinforcement was preheated to 300 ºC – 400 ºC for 1 hour before pouring in to the melt of
Al356. Al2O3 were poured centrally into the vortex at
0.5 g/s feed rate.

Nair and Joshi (2015) fabricated aluminium matrix composite (AMC) using stir casting
technique, where Al 6061 was the base metal and 10 wt. % silicon carbide (SiC) in powder
form with 320 mesh size was the reinforcement material. Al 6061 was melted in a graphite
crucible at around 650º C. Into the molten matrix, 10 wt. % SiC powder of 100 mesh size was
added. 1% Magnesium powder was also added in order to improve the wettability and decrease
the porosity. Stirrer was made out of graphite rod of 100 mm length and 25 mm diameter for
stirring. External threading was done on the stirrer. An internally threaded 3 feet long stainless

6
steel rod was fitted over this stirrer. The mixture was mechanically stirred using a motor of
around 250 RPM for 10 minutes before pouring into the mould. The AMC mixture was poured
into the mould and allowed to solidify for some time.

Anis et al. (2014) developed the metal matrix composite Al-10%MoO3 by stir casting method.
They used MoO3 is used as reinforcement and aluminium (98.41%) as matrix. Aluminium
powder was heated at 900°C. This metal-matrix composite is then poured into the graphite
crucible winded with resistive heating coil at 760°C. 10% of reinforcement was added and
stirred the composite by using the stir casting machine. The stirrer is exactly plus sign blade
having zigzag angle 90° of each side. Automatic stirring was carried out for 10 minutes with
normal 400 rpm of stirring rate.

Jailania et al. (2013) selected SiC particle reinforced aluminium alloy to produce metal matrix
composites (MMC) using different of parameters blade angle and stirring speed, also different
composition of SiC reinforcement. After the experimental settling up the aluminium alloy was
heated in the induction furnace until it melt, the impeller was set at the angle of 30° and the
stirring speed was 50 rpm to mix the SiC reinforcement. The SiC reinforced aluminium alloys
is stirred for 15 to 20 minutes. Then the mixture is poured into the mould to prepare some
specimens. The result of the experiment showed that the composite with 10 wt. % SiC at blade
angle of 30o and stirring speed of 100 rpm gave has metallurgical properties. Results revealed
that during lower speed and lower stir time particle clustering occurred in some places, and
some places were identified without SiC inclusion. It was found that by increasing the stirring
speed and stirring time better homogeneous distribution of SiC in the Al matrix. Better
distributions of SiC were found at blade angle of 30º, stirring speed of 100 rpm and 10% SiC.

Paul and Sijo (2015) investigated the effect of stirrer parameter on aluminium alloy (LM6)
reinforced SiC MMC produced by stir casting method. Aluminium was preheated for 3 to 4
hours at 450°C and silicon carbide also with 900°C. At first heater temperature is set to 500°C
and then it was gradually increased up to 900ºC. Temperature of the heater was set to 620ºC
which is below the melting temperature of the matrix. An electrical resistance furnace
assembled with stainless steel impeller with 2 blade, 4 blade and 5 blade used as stirrer was
used for stirring purpose. A uniform semisolid stage of the molten matrix was achieved by
stirring it at 600 rpm. Pouring of preheated reinforcement at the semisolid stage of the matrix
enhance the wettability of reinforcement, reduces the particle settling at the bottom of the
crucible. After stirring for 10 minutes at semisolid stage slurry was reheated and hold at a
temperature 900°C to make slurry in liquid state. Stirrer rpm was then gradually lowered to the

7
zero. The molten composite slurry was then poured in to the metallic mould which is preheated
at temperature 500°C this makes sure that the slurry is in molten condition throughout the
pouring. Results indicates that composite fabricated using four blade stirrer shows better
properties than two blade and five blade.

Hashim et al. (2002) studied the effect of stirring parameters such as stirring speed and impeller
position on the flow pattern of particles in the crucible during stir casting. The rotational speeds
used were in the range 50-1000 rpm for four different height of 10, 20, 50 and 70% of the
height, as measured from the crucible base. He found that turbulence at the base region of the
crucible which would give effective mixing of SiC particles.

Unal et al. (2012) investigated the effect of ultrasonic treatment during casting of a
hypereutectic Al-Si alloy containing 18%Si on the microstructure and mechanical properties.
Ultrasonic vibration was applied to the solidifying melt inside a laboratory type ultrasonic bath
containing water (60°C). Ultrasonic vibration of 40000 Hz and 500 W was applied to mold
externally for 25-30seconds.

Jia and Nastac (2013) studied the effect of ultrasonic treatment on the Solidification
Microstructure and Mechanical Properties of A356 Alloy. The setup consists of an 18 kHz and
power of 4000 W ultrasonic generator, a transducer of cylindrical and material of probe was
Nb (40 mm diameter), a control panel (for power and frequency adjustments) and an induction
furnace that is used to melt the A356 alloy. By using the Ultrasonic treatment the tensile
strength increased by at least 10% and the elongation levels by at least 20% in all studied
samples when compared to the ones without the UST treatment.

Ferguson et al. (2014) studied the effects of cavitation, pouring temperature, and cooling rate
on the grain size in Al-A356 castings. The system contains power of 600 W maximum, and
frequency of 20000 Hz. The melt temperature was brought to 700 °C in an electric muffle
furnace; then the Ultrasound horn was inserted in the melt and held in place for 5 min to treat
the sample at intensities of 0%, 20%, 40% and 60% of the maximum power (600 W).

Gupta et al. (2013) investigated the effect of ultrasonic stirring in aluminum matrix
composites. They performed experiments by employing four different conditions which were
carbon black addition accompanied with mechanical stirring, carbon black addition
accompanied with ultrasonic stirring, ultrasonic stirring but no carbon black addition and
control specimen (without ultrasonic stirring and no carbon black addition). The power of
ultrasonic generator was 1500 W and frequency of 20000 Hz. they conclude that Ultrasonic

8
stirring prevents SiC agglomeration and reduce porosity levels, and combined effect of
Ultrasonic stirring and carbon addition improve hardness.

Chen et al. (2015) studied the effect of Ultrasonic treatment on microstructural and mechanical
properties of cast magnesium alloys. The Ultrasonic generator with power capacity of 1000 W
and frequency of 20000 and 15000 Hz was used. The effects of grain refinement increase with
increasing acoustic frequency, acoustic power, and treatment time. The results of grain
refinement gradually vanish with increased settling time of the melts after ultrasonic treatment.
The addition of fine MgO particles can provide nucleation sites for grain formation during
solidification, and prevent grain growth, resulting in the refinement of the grains in cast
magnesium.

Zhang et al. (2015) studied the heat transfer in ultrasonic processing of steel melt. The
temperature field was simulated when the metal melt was treated with and without ultrasound.
The Ultrasound was introduced from the bottom of melt to avoid the erosion of high
temperature. It is found that the temperature of melt apparently increases when processed with
ultrasound. The Power of the ultrasonic generator was adjustable in the range of 0-300 W (in
step of 0-150-200-300) and ultrasonic frequency was set 20000 Hz.

Jiyu et al. (2015) have fabricated TiN/Al composites. The process involved the addition of
large size TiN particles (average particle size of 264 μm) into Al melt at 760˚C. In the meantime,
ultrasonic vibration was applied into the melt to comminute the large size TiN particles and
disperse the produced fine TiN particles simultaneously. The ultrasonic vibration was applied
to the aluminum melt for approximately 20 min until the aluminum is solidifying in the furnace.

Harichandran and Selvakumar (2015) studied the effect of B4C particle (nano/micro) on the
mechanical properties of aluminium metal matrix composites fabricated by ultrasonic assisted
solidification process. The ultrasonic generator with power capacity of 2000 W and frequency
of 20000 Hz was used. Initial Melt was mechanically stirred for 10 min than ultrasonic
treatment was applied. B4C particle was added in a fraction of 2, 4, 6, 8, 10 % by weight.

Huang et al. (2014) studied the effect of ultrasonic melt treatment on the macrostructure of
solidified high purity aluminium by experimentally using metallographic method. Numerical
calculations of acoustic pressure and velocity distribution in the melt were done using
COMSOL multiphysics software. The Ultrasonic generator operated at a fixed 20000 Hz
frequency and Power output of 1000 W.

9
Kang et al. (2014) have compared the effect of the ultrasonic treatment in different metal melts.
The ultrasonic streaming in water, aluminium and steel melts was numerically simulated and
compared. The ultrasonic streaming phenomenon in water, aluminium melt and steel melt was
numerically simulated through the CFD (Computational Fluid Dynamics) software Fluent and
the results for water were validated experimentally. The ultrasonic streaming and cavitation
results in these fluids were compared and analysed. The ultrasound with power of 200 W and
frequency of 20000 Hz was used.

Summary of Literature Review

Metal matrix composite made by stir casting are affected by many factors based on its
characterization and process like stirring speed, viscosity, blade design, crucible design,
clearance from bottom of crucible to stirrer blade, pouring temperature, size of reinforcement,
stirring time.

Clustering of particles occur on the upper side of melt in conventional stir casting method. It
was observed that few particles remain at bottom of the crucible after mechanically stirring and
did not mix properly in the melt.
When the ultrasound is introduced, the positive and negative pressure alternate in the fluid, if
the negative pressure reaches the threshold of cavitation, ultrasonic cavitation will occur in the
fluid.
Maximum cavitation zone should be required for uniform particle distribution.

Goal

To optimaize the maximum cavitation zone.

10
 CHAPTER 2
DESIGN: ANALYSIS, DESIGN METHODOLOGY AND
IMPLEMENTATION STRATEGY.
2.1 AEIOU Canvas

Fig 1. AEIOU Canvas

2.2 Ideation Canvas

Fig 2. Ideation Canvas

11
2.3 Empathy Canvas

Fig 3. Empathy Canvas

2.4 Product Development Canvas

Fig 4. Product Development Canvas

12
 CHAPTER 3
MODEL FORMULATION AND ANALYSIS
Finite element method (FEM) based COMSOL multiphysics is used to obtain the acoustic
pressure, absolute pressure, cavitation field and velocity of flow.

3.1 Introduction to COMSOL

COMSOL Multiphysics is a general-purpose software platform, based on advanced numerical

methods, for modelling and simulating physics-based problems. With COMSOL Multiphysics,
we will be able to account for coupled or multiphysics phenomena.

3.2 Steps to solving problem

Fig 4. Flow process to approach problem

Fig 4. shows step by step procedure to solve the problem. It consist Component, Geometry,
Materials, Physics, Meshing, Study, Results. COMSOL Multiphysics provides 1D, 2D, and 3D
geometry modelling tools. All geometry operations are organized in a parametric sequence of
operations in the Model Tree.
13
3.2.1 Physics (Module)

The Acoustics Module consists of a set of physics interfaces, which enable to simulate the
propagation of sound in fluids and in solids. The available physics interfaces include Pressure
acoustics, Acoustic-solid interaction, Aeroacoustics, Thermoacoustics, and Geometrical

acoustics.

3.2.2 Boundary Conditions

Fig 5. Boundary Conditions

14
Pressure Acoustic Module:

2∗𝜌∗𝑐∗𝑊
𝑃𝑠 = √( )
𝜋𝑅 2

3.3 Mathematical model:

The numerical simulation of acoustic wave in water, diethyl ether, ethanol, ethylene glycol,
glycerol and toluene is carried out in COMSOL multiphysics software by using Frequency
based Pressure Acoustic Module. Two Dimensional model is used for analysis. The booster of
6 mm diameter are submerged 20mm vertically in to the metal pool in container. The height of
liquid pool is 70 mm and diameter of 80 mm (300 ml of water). The ultrasound with power of
300W having frequency 20000 Hz is introduced into the liquid pool along the gravity direction.

Following cases are taken for simulation work.

1. 300W, 6mm Diameter of Probe, Water.

2. 300W, 6mm Diameter of Probe, Diethyl Ether.

3. 300W, 6mm Diameter of Probe, Ethanol.

4. 300W, 6mm Diameter of Probe, Ethylene Glycol.

5. 300W, 6mm Diameter of Probe, Glycerol.

6. 300W, 6mm Diameter of Probe, Toluene.

Acoustic power input was transformed to a pressure source boundary as 𝑃𝑠 .

15
 2∗𝜌∗𝑐∗𝑊
𝑃𝑠 = √( )
𝜋𝑅 2

Where, W is the applied ultrasonic power and R is the end face radius of the sonotrode.

A very important parameter of the ultrasonic field one that determines to a great extent the
efficiency of processing is the ultrasonic intensity I. In the simplest case of a plane wave, the
intensity (W/m2) is given by,
W
I= S

Where, W is power, S is area of sonotrode tip.

The sonotrode face excites predominantly traveling waves propagating through the melt. The
amplitude, oscillation velocity, acceleration, and sound pressure of these waves are connected
with sound intensity I and frequency f by the following relations (Eskin, 1997).

1 2𝐼
A = 2𝜋𝑓 √𝜌𝑐

2𝐼
V = √𝜌𝑐

𝑃𝑠 = √2𝐼𝜌𝑐

From the above equations, it can be said that as intensity changes, the amplitude, oscillation
velocity, acceleration and power changes.

Table 1. Parameter and Value

Parameters Expression Value
Power W 300 W
Frequency f 20000 Hz
Density of Water 𝜌𝑤 1000 kg⁄m3
Density of Diethyl Ether 𝜌𝑑𝑒 713 kg⁄m3
Density of Ethanol 𝜌𝑒 789 kg⁄m3
Density of Ethylene Glycol 𝜌𝑒𝑔 1113 kg⁄m3
Density of Glycerol 𝜌𝑔 1260 kg⁄m3
Density of Toluene 𝜌𝑡 867 kg⁄m3
Radius of probe r 0.003 m
Speed of sound in water 𝑐𝑤 1493 𝑚⁄𝑠
Speed of sound in Diethyl Ether 𝑐𝑑𝑒 985 𝑚⁄𝑠
Speed of sound in Ethanol 𝑐𝑒 1207 𝑚⁄𝑠
Speed of sound in Ethylene Glycol 𝑐𝑒𝑔 1658 𝑚⁄𝑠
Speed of sound in Glycerol 𝑐𝑔 1904 𝑚⁄𝑠
Speed of sound in Toluene 𝑐𝑡 1328 𝑚⁄𝑠
Impedance of Glass 𝑍𝑔𝑙𝑎𝑠𝑠 10920000 Pa. s⁄m2
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3.4 Numerical calculation of acoustic parameter

Six different types of medium going to treat are water, diethyl ether, ethanol, ethylene glycol,
glycerol and toluene.

3.4.1 At 300W for 6mm diameter in water

Intensity I is given by,

𝑊 300 300
𝐼= = 𝜋𝑟 2 = 𝜋(0.006)2 = 2652582.38 W/𝑚2
𝑆

Acoustic Pressure Ps is given by,

Ps=√2𝐼𝜌𝑐 = √2 ∗ 2652582.38 ∗ 1000 ∗ 1500 =2820947.92 Pa

3.4.2 At 300W for 6mm diameter in Diethyl ether

Intensity I is given by,

𝑊 300 300
𝐼= = 𝜋𝑟 2 = 𝜋(0.006)2 = 2652582.38 W/𝑚2
𝑆

Acoustic Pressure Ps is given by,

Ps=√2𝐼𝜌𝑐 = √2 ∗ 2652582.38 ∗ 713 ∗ 985 = 1930244.47 Pa

3.4.3 At 300W for 6mm diameter in Ethanol

Intensity I is given by,

𝑊 300 300
𝐼= = 𝜋𝑟 2 = 𝜋(0.006)2 = 2652582.38 W/𝑚2
𝑆

Acoustic Pressure Ps is given by,

Ps=√2𝐼𝜌𝑐 = √2 ∗ 2652582.38 ∗ 789 ∗ 1207 = 2247716.71 Pa

3.4.3 At 300W for 6mm diameter in Toluene

Intensity I is given by,

𝑊 300 300
𝐼= = 𝜋𝑟 2 = 𝜋(0.006)2 = 2652582.38 W/𝑚2
𝑆

Acoustic Pressure Ps is given by,

Ps=√2𝐼𝜌𝑐 = √2 ∗ 2652582.38 ∗ 865 ∗ 1328 = 2468632.99 Pa

17
3.4.4 At 300W for 6mm diameter in Ethylene Glycol

Intensity I is given by,

𝑊 300 300
𝐼= = 𝜋𝑟 2 = 𝜋(0.006)2 = 2652582.38 W/𝑚2
𝑆

Acoustic Pressure Ps is given by,

Ps=√2𝐼𝜌𝑐 = √2 ∗ 2652582.38 ∗ 1113 ∗ 1658 = 2212454.18 Pa

3.4.5 At 300W for 6mm diameter in Glycerol

Intensity I is given by,

𝑊 300 300
𝐼= = 𝜋𝑟 2 = 𝜋(0.006)2 = 2652582.38 W/𝑚2
𝑆

Acoustic Pressure Ps is given by,

Ps=√2𝐼𝜌𝑐 = √2 ∗ 2652582.38 ∗ 1260 ∗ 1904 = 3567534.50 Pa

Table shows the values of ultrasonic intensity, acoustic pressure and amplitude for the water,
diethyl ether, ethanol, ethylene glycol, glycerol and toluene.

Table 2. Calculated values of acoustic pressure in different liquids

Sr. Ultrasonic Intensity

Medium Pressure (MPa)
No. (W/𝒎𝟐 )
1 Water 10615711 5.86
2 Diethyl Ether 10615711 3.86
3 Ethanol 10615711 4.5
4 Ethylene Glycol 10615711 6.26
5 Glycerol 10615711 7.14
6 Toluene 10615711 4.94

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Simulation Results

Sr. Medium Velocity obtained of Fluid Pressure (MPa)

No. Flow (m/s)
Max Min
1 Water 9.26 0.26 5.86
2 Diethyl Ether 13.99 0.37 3.86
3 Ethanol 4.87 0.14 4.5
4 Ethylene Glycol 10.03 0.29 6.26
5 Glycerol 7.84 0.24 7.14
6 Toluene 5.57 0.27 4.94

4.5 Results

A simulation results gives acoustic and velocity fluid flow.

4.5.1 Acoustic pressure

Absolute Pressure in water

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Absolute Pressure in Diethyl Ether

Absolute Pressure in Ethanol

20
Absolute Pressure in Ethylene Glycol

Absolute Pressure in Glycerol

21
 Absolute Pressure in Toluene

4.5.2 Velocity contour of fluid flow

Velocity contour of Water

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Velocity contour of Diethyl Ether

Velocity contour of Ethanol

23
Velocity contour of Ethylene Glycol

Velocity contour of Glycerol

24
Velocity contour of Toluene

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 CHAPTER 4
CONCLUSIONS
Analysis of ultrasonic treatment in water, diethyl ether, ethanol, ethylene glycol, glycerol and
toluene is simulated.
From the simulation results one can easily find the area of cavitation zone. Fig show the
cavitation zone in different liquids, but low intensity power (300W) does not create that much
power to produce cavitation zone.

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 Diethyl ether Ethanol

Ethylene glycol Glycerol

Toluene Water

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 REFERENCES
In the alphabetic ascending order
Citations to be provided throughout the Report.

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