Comparison of frequency domain and time domain methods for the numerical simulation of contactless ultrasonic...

The use of a top-mounted electromagnetic induction coil has been demonstrated as a contactless alternative to traditional ultrasonic treatment (UST) techniques that use an immersed mechanical sonotrode for the treatment of metals in the liquid state. This method offers similar benefits to existing UST approaches, including degassing, grain refinement, and dispersion of nanoparticles, while also preventing contact contamination due to erosion of the sonotrode. Contactless treatment potentially extends UST to high temperature or reactive melts. Generally, the method relies on acoustic resonance to reach pressure levels suitable for inertial cavitation and as a result the active cavitation volume tends to lie deep in the melt rather than in the small volume surrounding the immersed sonotrode probe. Consequently, (i) with suitable tuning of the coil supply frequency for resonance, the treatment volume can be made arbitrarily large, (ii) the problem of shielding and pressure wave attenuation suffered by the immersed sonotrode is avoided. However, relying on acoustic resonance presents problems: (i) the emergence of bubbles alters the speed of sound, resonance is momentarily lost, and cavitation becomes intermittent, (ii) as sound waves travel through and reflect on all the materials surrounding the melt, the sound characteristics of the crucible and supporting structures need to be carefully considered. The physics of cavitation coupled with this intermittent behaviour poses a challenge to sonotrode modelling orthodoxy, a problem we are trying to address in this publication. Two alternative approaches will be discussed, one of which is in the time domain and one in the frequency domain, which couple the solution of a bubble dynamics solver with that of an acoustics solver, to give an accurate prediction of the acoustic pressure generated by the induction coil. The time domain solver uses a novel algorithm to improve simulation time, by detecting an imminent bubble collapse and prescribing its subsequent behaviour, rather than directly solving a region that would normally require extremely small time steps. This way, it is shown to predict intermittent cavitation. The frequency domain solver for the first time couples the nonlinear Helmholtz model used for studying cavitation, with a background source term for the contribution of Lorentz forces. It predicts comparable RMS pressures to the time domain solver, but not the intermittent behaviour due to the underlying harmonic assumption. As further validation, the frequency domain method is also used to compare the generated acoustic pressure with that of traditional UST using a mechanical sonotrode.