Ultrasonic horn

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Conventional Converging Ultrasonic Horn, produced by Industrial Sonomechanics, LLC Conventional Converging Horn.jpg
Conventional Converging Ultrasonic Horn, produced by Industrial Sonomechanics, LLC
Full-wave Barbell Ultrasonic Horn, produced by Industrial Sonomechanics, LLC Full-wave Barbell Horn.jpg
Full-wave Barbell Ultrasonic Horn, produced by Industrial Sonomechanics, LLC

An ultrasonic horn (also known as acoustic horn, sonotrode , acoustic waveguide , ultrasonic probe) is a tapering metal bar commonly used for augmenting the oscillation displacement amplitude provided by an ultrasonic transducer operating at the low end of the ultrasonic frequency spectrum (commonly between 15 and 100 kHz). The device is necessary because the amplitudes provided by the transducers themselves are insufficient for most practical applications of power ultrasound. [2] Another function of the ultrasonic horn is to efficiently transfer the acoustic energy from the ultrasonic transducer into the treated media, [3] which may be solid (for example, in ultrasonic welding, ultrasonic cutting or ultrasonic soldering) or liquid (for example, in ultrasonic homogenization, sonochemistry, milling, emulsification, spraying or cell disruption). [1] Ultrasonic processing of liquids relies of intense shear forces and extreme local conditions (temperatures up to 5000 K and pressures up to 1000 atm) generated by acoustic cavitation. [2]

Sonotrode sonotrode

In ultrasonic machining, welding and mixing, a sonotrode is a tool that creates ultrasonic vibrations and applies this vibrational energy to a gas, liquid, solid or tissue.

Waveguide structure that guides waves, typically electromagnetic waves

A waveguide is a structure that guides waves, such as electromagnetic waves or sound, with minimal loss of energy by restricting expansion to one dimension or two. There is a similar effect in water waves constrained within a canal, or guns that have barrels which restrict hot gas expansion to maximize energy transfer to their bullets. Without the physical constraint of a waveguide, wave amplitudes decrease according to the inverse square law as they expand into three dimensional space.

A transducer is a device that converts energy from one form to another. Usually a transducer converts a signal in one form of energy to a signal in another.

Contents

Description

The ultrasonic horn is commonly a solid metal rod with a round transverse cross-section and a variable-shape longitudinal cross-section - the rod horn. Another group includes the block horn, which has a large rectangular transverse cross-section and a variable-shape longitudinal cross-section, and more complex composite horns. [4] The devices from this group are used with solid treated media. The length of the device must be such that there is mechanical resonance at the desired ultrasonic frequency of operation – one or multiple half wavelengths of ultrasound in the horn material, with sound speed dependence on the horn’s cross-section taken into account. In a common assembly, the ultrasonic horn is rigidly connected to the ultrasonic transducer using a threaded stud.

Ultrasonic horns may be classified by the following main features: 1) Longitudinal cross-section shape – stepped, exponential, conical, catenoidal, etc. 2) Transverse cross-section shape – round, rectangular, etc. 3) Number of elements with different longitudinal cross-section profile – common and composite. [3] [5] A composite ultrasonic horn has a transitional section with a certain longitudinal cross-section shape (non-cylindrical), positioned between cylindrical sections.

Horn transitional section shapes.jpg
Longitudinal cross-sections of simple half-wavelength ultrasonic horns: 1 – conical, 2 – exponential or catenoidal, 3 - stepped. In all figures: V(z) and e(z) - distributions of amplitude and deformation
Converging horn amplitude and stress distributions.jpg
Longitudinal cross-section of a round composite converging half-wave ultrasonic horn, where L1,L3 – cylindrical sections, L2 – catenoidal transitional section
Barbell horn amplitude and stress distributions.jpg
Longitudinal cross-section of a round full-wave Barbell horn, where L1, L3, L5 – cylindrical sections, L2 – exponential transitional section, L4 – conical transitional section
A horn in an ultrasonic drill from 1955. The horn, the long tapering steel rod at center, couples the ultrasonic transducer in the housing at top to the tool which presses against the workpiece on the worktable at bottom. Ultrasonic drill 1955.jpg
A horn in an ultrasonic drill from 1955. The horn, the long tapering steel rod at center, couples the ultrasonic transducer in the housing at top to the tool which presses against the workpiece on the worktable at bottom.

Frequently, an ultrasonic horn has a transitional section with a longitudinal cross-section profile that converges towards the output end. Thus, the horn’s longitudinal oscillation amplitude increases towards the output end, while the area of its transverse cross-section decreases. [6] Ultrasonic horns of this type are used primarily as parts of various ultrasonic instruments for ultrasonic welding, ultrasonic soldering, cutting, making surgical tools, molten metal treatment, etc. Converging ultrasonic horns are also commonly included in laboratory liquid processors used for a variety of process studies, including sonochemical, emulsification, dispersing and many others. [7]

Ultrasonic welding welding process

Ultrasonic welding is an industrial technique whereby high-frequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a solid-state weld. It is commonly used for plastics and metals, and especially for joining dissimilar materials. In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together. When applied to metals, a notable characteristic of this method is that the temperature stays well below the melting point of the involved materials.

Ultrasonic soldering is a flux-less soldering process that uses ultrasonic energy, without the need for chemicals to solder materials, such as glass, ceramics, and composites, hard to solder metals and other sensitive components which cannot be soldered using conventional means. Ultrasonic (U/S) soldering, as a flux-less soldering process, is finding growing application in soldering of metals and ceramics from solar photovoltaics and medical shape memory alloys to specialized electronic and sensor packages. U/S soldering has been reported since 1955 as a method to solder aluminum and other metals without the use of flux.

In chemistry, the study of sonochemistry is concerned with understanding the effect of ultrasound in forming acoustic cavitation in liquids, resulting in the initiation or enhancement of the chemical activity in the solution. Therefore, the chemical effects of ultrasound do not come from a direct interaction of the ultrasonic sound wave with the molecules in the solution.

In high-power industrial ultrasonic liquid processors, [8] such as commercial sonochemical reactors, ultrasonic homogenizers and ultrasonic milling systems intended for the treatment of large volumes of liquids at high ultrasonic amplitudes (ultrasonic mixing, production of nanoemulsions, solid particle dispersing, ultrasonic nanocrystallization, etc.), the preferred ultrasonic horn type is the Barbell horn. [7] Barbell horns are able to amplify ultrasonic amplitudes while retaining large output diameters and radiating areas. It is, therefore, possible to directly reproduce laboratory optimization studies in a commercial production environment by switching from Converging to Barbell horns while maintaining high ultrasonic amplitudes. If correctly scaled up, the processes generate the same reproducible results on the plant floor as they do in the laboratory. [7]

Maximum achievable ultrasonic amplitude depends, primarily, on the properties of the material from which an ultrasonic horn is made as well as on the shape of its longitudinal cross-section. Commonly, the horns are made from titanium alloys, such as Ti6Al4V, stainless steel, such as 440C, and, sometimes, aluminum alloys or powdered metals. The most common and simple to make transitional section shapes are conical and catenoidal.

Stainless steel steel alloy resistant to corrosion

In metallurgy, stainless steel, also known as inox steel or inox from French inoxydable (inoxidizable), is a steel alloy, with highest percentage contents of iron, chromium, and nickel, with a minimum of 10.5% chromium content by mass and a maximum of 1.2% carbon by mass.

Catenoid type of surface in topology, arising by rotating a catenary curve about an axis

A catenoid is a type of surface, arising by rotating a catenary curve about an axis. It is a minimal surface, meaning that it occupies the least area when bounded by a closed space. It was formally described in 1744 by the mathematician Leonhard Euler.

Applications

Plastics

Consumer products, automotive components, medical devices and most all industries utilize Ultrasonics. Metal inserts may be secured in plastic and dissimilar materials can often be bonded with proper tooling design. Ultrasonic horns come in a variety of shapes and designs, but all must be tuned to a specific operating frequency; the most common being 15 kHz, 20 kHz, and 40 kHz.

Ultrasonic welding utilizes high frequency, vertical motion to produce heat and the flow of thermoplastic material at the interface of mated parts. Pressure is maintained after the delivery of energy is stopped to allow re-solidification of interwoven plastic at the joint, securing the parts with a homogeneous or mechanical bond. This process offers an environmentally friendly means of assembly as opposed to conventional adhesives or mechanical fasteners. [9]

Related Research Articles

Acoustics science that deals with the study of all mechanical waves in gases, liquids, and solids including vibration, sound, ultrasound and infrasound

Acoustics is the branch of physics that deals with the study of all mechanical waves in gases, liquids, and solids including topics such as vibration, sound, ultrasound and infrasound. A scientist who works in the field of acoustics is an acoustician while someone working in the field of acoustics technology may be called an acoustical engineer. The application of acoustics is present in almost all aspects of modern society with the most obvious being the audio and noise control industries.

Ultrasound vibrations with frequencies above the human hearing range

Ultrasound is sound waves with frequencies higher than the upper audible limit of human hearing. Ultrasound is not different from "normal" (audible) sound in its physical properties, except that humans cannot hear it. This limit varies from person to person and is approximately 20 kilohertz in healthy young adults. Ultrasound devices operate with frequencies from 20 kHz up to several gigahertz.

Surface acoustic wave acoustic wave traveling along the surface of a material exhibiting elasticity, with an amplitude that typically decays exponentially with depth into the substrate

A surface acoustic wave (SAW) is an acoustic wave traveling along the surface of a material exhibiting elasticity, with an amplitude that typically decays exponentially with depth into the material.

Sonication application of ultrasound

Sonication is the act of applying sound energy to agitate particles in a sample, for various purposes such as the extraction of multiple compounds from plants, microalgae and seaweeds. The enhancement in the extraction of bioactive compounds achieved using sonication is attributed to cavitation in the solvent, a process that involves nucleation, growth, and collapse of bubbles in a liquid, driven by the passage of the ultrasonic waves. Ultrasonic frequencies (>20 kHz) are usually used, leading to the process also being known as ultrasonication or ultra-sonication.

Ultrasonic cleaning process that uses ultrasound and a cleaning solvent to clean items

Ultrasonic cleaning is a process that uses ultrasound to agitate a fluid. The ultrasound can be used with just water, but use of a solvent appropriate for the item to be cleaned and the type of soiling present enhances the effect. Cleaning normally lasts between three and six minutes, but can also exceed 20 minutes, depending on the object to be cleaned.

Ultrasonic testing testing techniques based in the propagation of ultrasonic waves in the object or material tested

Ultrasonic testing (UT) is a family of non-destructive testing techniques based on the propagation of ultrasonic waves in the object or material tested. In most common UT applications, very short ultrasonic pulse-waves with center frequencies ranging from 0.1-15 MHz, and occasionally up to 50 MHz, are transmitted into materials to detect internal flaws or to characterize materials. A common example is ultrasonic thickness measurement, which tests the thickness of the test object, for example, to monitor pipework corrosion.

Ultrasound is sound waves with frequencies higher than the upper audible limit of human hearing.

Megasonic cleaning is a type of acoustic cleaning, related to ultrasonic cleaning. It is a gentler cleaning mechanism, less likely to cause damage, and is used in wafer, medical implant, and industrial part cleaning.

Ultrasonic transducer

Ultrasonic transducers or ultrasonic sensors are a type of acoustic sensor divided into three broad categories: transmitters, receivers and transceivers. Transmitters convert electrical signals into ultrasound, receivers convert ultrasound into electrical signals, and transceivers can both transmit and receive ultrasound.

Electromagnetic acoustic transducer

Electromagnetic acoustic transducer (EMAT) is a transducer for non-contact sound generation and reception using electromagnetic mechanisms. EMAT is an ultrasonic nondestructive testing (NDT) method which does not require contact or couplant, because the sound is directly generated within the material adjacent to the transducer. Due to this couplant-free feature, EMAT is particularly useful for automated inspection, and hot, cold, clean, or dry environments. EMAT is an ideal transducer to generate Shear Horizontal (SH) bulk wave mode, Surface Wave, Lamb waves and all sorts of other guided-wave modes in metallic and/or ferromagnetic materials. As an emerging ultrasonic testing (UT) technique, EMAT can be used for thickness measurement, flaw detection, and material property characterization. After decades of research and development, EMAT has found its applications in many industries such as primary metal manufacturing and processing, automotive, railroad, pipeline, boiler and pressure vessel industries.

Acoustic microscopy is microscopy that employs very high or ultra high frequency ultrasound. Acoustic microscopes operate non-destructively and penetrate most solid materials to make visible images of internal features, including defects such as cracks, delaminations and voids.

Guided wave testing

Guided wave testing (GWT) is a non-destructive evaluation method. The method employs acoustic waves that propagate along an elongated structure while guided by its boundaries. This allows the waves to travel a long distance with little loss in energy. Nowadays, GWT is widely used to inspect and screen many engineering structures, particularly for the inspection of metallic pipelines around the world. In some cases, hundreds of meters can be inspected from a single location. There are also some applications for inspecting rail tracks, rods and metal plate structures.

Ultrasonic impact treatment (UIT) is a metallurgical processing technique, similar to work hardening, in which ultrasonic energy is applied to a metal object. This technique is part of the High Frequency Mechanical Impact (HFMI) processes. Other acronyms are also equivalent: Ultrasonic Needle Peening (UNP), Ultrasonic Peening (UP). Ultrasonic impact treatment can result in controlled residual compressive stress, grain refinement and grain size reduction. Low and high cycle fatigue are enhanced and have been documented to provide increases up to ten times greater than non-UIT specimens.

A capacitive micromachined ultrasonic transducer (CMUT) is a relatively new concept in the field of ultrasonic transducers. Most of the commercial ultrasonic transducers today are based on piezoelectricity. CMUTs are the transducers where the energy transduction is due to change in capacitance. CMUTs are constructed on silicon using micromachining techniques. A cavity is formed in a silicon substrate, and a thin layer suspended on the top of the cavity serves as a membrane on which a metallized layer acts an electrode, together with the silicon substrate which serves as a bottom electrode.

Ultrasonic antifouling is a technology that helps reduce fouling on underwater structures, through using small-scale acoustic cavitation to destroy, denature and discourage attachment of algae and other single-celled organisms.

Sonoelectrochemistry is the application of ultrasound in electrochemistry. Like sonochemistry, sonoelectrochemistry was discovered in the early 20th century. The effects of power ultrasound on electrochemical systems and important electrochemical parameters were originally demonstrated by Moriguchi and then by Schmid and Ehert when the researchers investigated the influence of ultrasound on concentration polarisation, metal passivation and the production of electrolytic gases in aqueous solutions. In the late 1950s, Kolb and Nyborg showed that the electrochemical solution hydrodynamics in an electrochemical cell was greatly increased in the presence of ultrasound and described this phenomenon as acoustic streaming. In 1959, Penn et al. demonstrated that sonication had a great effect on the electrode surface activity and electroanalyte species concentration profile throughout the solution. In the early 1960s, the electrochemist Allen J. Bard showed in controlled potential coulometry experiments that ultrasound significantly enhances mass transport of electrochemical species from the bulk solution to the electroactive surface. In the range of ultrasonic frequencies [20 kHz – 2 MHz], ultrasound has been applied to many electrochemical systems, processes and areas of electrochemistry both in academia and industry, as this technology offers several benefits over traditional technologies. The advantages are as follows: significant thinning of the diffusion layer thickness (δ) at the electrode surface; increase in electrodeposit/electroplating thickness; increase in electrochemical rates, yields and efficiencies; increase in electrodeposit porosity and hardness; increase in gas removal from electrochemical solutions; increase in electrode cleanliness and hence electrode surface activation; lowerering in electrode overpotentials ; and suppression in electrode fouling.

References

  1. 1 2 3 Industrial Sonomechanics website, 2011
  2. 1 2 Peshkovsky, S.L. and Peshkovsky, A.S., "Shock-wave model of acoustic cavitation", Ultrason. Sonochem., 2008. 15: p. 618–628.
  3. 1 2 Peshkovsky, S.L. and Peshkovsky, A.S., "Matching a transducer to water at cavitation: Acoustic horn design principles", Ultrason. Sonochem., 2007. 14: p. 314–322.
  4. Sonic Power website
  5. Abramov, O.V., "High-intensity ultrasonics: theory and industrial applications", 1999: CRC Press. 692.
  6. "Ultrasonic Horn Designs and Properties", Industrial Sonomechanics website, 2011
  7. 1 2 3 "Barbell Horn Ultrasonic Technology", Industrial Sonomechanics website, 2011
  8. "Ultrasonic Liquid Processor Systems", Industrial Sonomechanics website, 2011
  9. "Ultrasonics", ToolTex.com, 2013

Further reading