Ultrasonic cavitation is used in various processes and applications, utilizing powerful shock waves and high-speed liquid jets generated by the collapsing bubbles. Typically, a single frequency source is used to produce the desired effects. However, optimization of the efficiency of ultrasound reactors is necessary to improve cavitation activity in specific applications such as for the exfoliation of two dimensional materials. This research takes the next step to investigate the effect of a dual frequency transducer system on the bubble dynamics, cavitation zone, pressure fields, acoustic spectra, and induced shock waves for four liquids with a range of physical properties. Using ultra-high-speed imaging and synchronized acoustic pressure measurements, the effect of ultrasonic dual frequencies on bubble dynamics was investigated. The addition of a high frequency transducer (1174 kHz) showed that the bubble fragments and satellite bubbles induced from a low frequency transducer (24 kHz) were able to extend their lifecycle and increase spatial distribution, thus, extending the boundaries of the cavitation zone. Furthermore, this combination of ultrasonic frequencies generated higher acoustic pressures (up to 180%) and enhanced the characteristic shock wave peak, indicating more bubble collapses and the generation of additional shock waves. The dual frequency system also enlarged the cavitation cloud size under the sonotrode. These observations specifically delineated the enhancement of cavitation activity using a dual frequency system pivotal for optimization of existing cavitation-based processing technologies.

This study experimentally investigates the role of cavitation-induced shock waves in initiating and destabilizing capillary (surface) waves on a droplet surface, preceding atomization. Acoustic emissions and interfacial wave dynamics were simultaneously monitored in droplets of different liquids (water, isopropyl alcohol and glycerol), using a calibrated fiber-optic hydrophone and high-speed imaging. Spectral analysis of the hydrophone data revealed distinct subharmonic frequency peaks in the acoustic spectrum correlated with the wavelength of capillary waves, which were optically captured during the onset of atomization from the repetitive imploding bubbles. This finding provides the first direct evidence that the wavelength of the growing surface waves, which governs capillary instability resulting in droplet breakup, is linked to the periodicity of shock waves responsible for the onset of the subharmonic frequencies detected in the acoustic spectra. This work contributes to a deeper understanding of ultrasonic atomization, signifying the role of cavitation and shock waves in the atomization process.

In this work, we implement a dual frequency (24 kHz and 1174 kHz) ultrasonic assisted liquid phase exfoliation (ULPE) technique in deionized water (DIW) and other eco-friendly solvents, to produce a variety of high-quality few-layer graphene (FLG) solutions under controlled ultrasonication conditions. The resulting FLG dispersions of variable sizes (∼0.2-1.5 μm²) confirmed by characterisation techniques comprising UV-Vis spectroscopy, Raman spectroscopy and high-resolution transmission electron microscopy (HR-TEM). For the first time we demonstrate that high yield of FLG flakes with minimal defects, stable for 6 + months in a solution (stability ∼ 70 %), can be obtained in less than 1-hour of treatment in either water/ethanol (DIW:EtOH) or water/isopropyl alcohol (DIW:IPA) eco-friendly mixtures. We also scrutinized the underlying mechanisms of cavitation using high-speed imaging synchronized with acoustic pressure measurements. The addition of ethanol or IPA to deionized water is proposed to play a central role in exfoliation as it regulates the extend of the cavitation zone, the intensity of the ultrasonic field and, thus, the cavitation effectiveness. Our study revealed that lateral sizes of the obtained FLG depend on the choice of exfoliating media and the diameter of a sonotrode used. This variability offers flexibility in producing FLG of different sizes, applicable in a wide spectrum of size-specific applications.

In recent years, ultrasonic processing (USP) technology has led to some of the most promising scientific breakthroughs in the field of pharmaceutical, food, environmental and material sciences leading to advancements in manufacturing, process efficiency, and material performance. However, the industrial scalability of USP still remains a key challenge, largely due to the lack of awareness, standardization and predictive multiphysics models. Optimizing this technology necessitates a bottom-up approach, emphasizing fundamental understanding of the physical phenomena at play prior to scaling-up. Despite the advancements of opto-acoustic characterization tools, the underlying root-cause driving these technological innovations remains unexplored. This paper provides a comprehensive overview of our work carried out in the last 5 years to uncover the fundamental mechanism that governs the deployment of USP in areas related to metal casting, additive manufacturing, production of nanomaterials and composites by employing in-situ high-speed visualizations techniques and characterization of acoustic emissions. The results presented and discussed in this article offer a new perspective on the pivotal role of cavitation-induced shock waves, shifting the focus from being just a by-product, to a primary driver of material modification during USP.