Effect of Experimental Parameters on Cavitation Dose in Ultrasonic Baths via Modified Aluminum Foil Test

Ultrasonic cavitation is a key mechanism in the dispersion and erosion of solid materials in liquids; however, the influence of processing conditions and medium properties on its efficiency in ultrasonic baths remains poorly systematized. Despite the widespread use of ultrasonic baths in materials processing, general optimization principles are lacking, and operating parameters are typically determined empirically for each system. In this work, cavitation activity was quantitatively assessed using an aluminum foil erosion test, with the foil clamped in a plastic frame to evaluate the mechanical effects of cavitation. The effects of ultrasonic power, frequency, treatment time, temperature, solvent nature, and vessel material on the foil mass loss were systematically investigated. The results demonstrate that both the instrumental parameters and physicochemical properties of the dispersion medium, including viscosity and surface tension, significantly affect the cavitation activity. Solvents with lower cavitation thresholds and favorable acoustic properties promote more intense erosion, while the vessel material and geometry also influence energy transmission to the liquid. This study provides a systematic framework for assessing the cavitation dose in ultrasonic baths and offers practical guidelines for optimizing ultrasonic dispersion processes and improving their reproducibility.