Ultrasonic (cavitation) melt processing attracts considerable interest from both academic and industrial communities as a promising route to provide clean, environment friendly and energy efficient solutions for some of the core issues of the metal casting industry, such as improving melt quality and providing structure refinement. In the last 5 years, the authors undertook an extensive research programme into fundamental mechanisms of cavitation melt processing using state-of-the-art and unique facilities and methodologies. This overview summarises the recent results on the evaluation of acoustic pressure and melt flows in the treated melt, direct observations and quantitative analysis of cavitation in liquid aluminium alloys, in-situ and ex-situ studies of the nucleation, growth and fragmentation of intermetallics, and de-agglomeration of particles. These results provide valuable new insights and knowledge that are essential for upscaling ultrasonic melt processing to industrial level.

A bespoke cavitometer that measures acoustic spectrum and is capable of operating in a range of temperatures (up to 750°C) was used to study the cavitation behaviour in three transparent liquids and in molten aluminium. To relate these acoustic measurements to cavitation development, the dynamics of the cavitation bubble structures was observed in three Newtonian, optically transparent liquids with significantly different physical properties: water, ethanol, and glycerine. Each liquid was treated at 20kHz with a piezoelectric ultrasonic transducer coupled to a titanium sonotrode with a tip diameter of 40mm. Two different transducer power levels were deployed: 50% and 100%, with the maximum power corresponding to a peak-to-peak amplitude of 17μm. The cavitation structures and the flow patterns were filmed with a digital camera. To investigate the effect of distance from the ultrasound source on the cavitation intensity, acoustic emissions were measured with the cavitometer at two points: below the sonotrode and near the edge of the experimental vessel. The behaviour of the three tested liquids was very different, implying that their physical parameters played a decisive role in the establishment of the cavitation regime. Non dimensional analysis revealed that water shares the closest cavitation behaviour with liquid aluminium and can therefore be used as its physical analogue in cavitation studies; this similarity was also confirmed when comparing the measured acoustic spectra of water and liquid aluminium.

This paper highlights the future perspectives of sustainable tribology by examining the economic, environmental and social impact of three tribological case studies. One case study examines the sustainability and durability of micro-CHP systems looking the tribological phenomena generated within a scroll expander system. The scroll is the main part of a specific micro-CHP system and experiences wear and cavitation damage. The tribological optimization of the scroll expander improves the sustainability of the micro-CHP unit while it has a serious economic and environmental impact to the consumers and to the society in general. Another case study is focused on friction and wear performance of lifeboat launch slipways. The causes of high friction and wear during the RNLI's lifeboat launches along an inclined slipway are investigated with a view to reducing the environmental impact due to slipway panel wear and lubricant release into the marine environment. The project encompasses the sustainable design of slipway panels using design modifications based on tribological investigations to double their lifespan, while environmental and economic impact was significantly reduced by the use of biodegradable greases and water as lubricants. The final case study involves an investigation of recycled plastic materials to replace polyurethane used on skateboard wheels, scooters and similar applications. Polyurethane (PU) is difficult to recycle. With the dwindling resources and environmental problems facing the world today, recycling for both waste reduction and resource preservation has become an increasingly important aspect of sustainability. The tribological results showed that recycled polycarbonate plastic can effectively act as a substitute to polyurethane wheels. Moreover, sustainability considerations showing the environmental benefits of the use of recycled plastics over PU include reducing the CO2 footprint by 50% and the energy consumed by 60%, among other benefits. These case studies emphasise the importance of sustainable tribology in our epoch showing that increased sustainability performance can be achieved through tribology to a significant extent in many cases, providing stability to our world and more viable long term growth to our societies

Acoustic streaming and its attendant effects in the sump of a direct-chill (DC) casting process are successfully predicted under ultrasonic treatment for the first time. The proposed numerical model couples acoustic cavitation, fluid flow, heat and species transfer, and solidification to predict the flow pattern, acoustic pressure, and temperature fields in the sump. The model is numerically stable with time steps of the order of 0.01 s and therefore computationally attractive for optimization studies necessitating simulation times of the order of a minute. The sump profile is altered by acoustic streaming, with the slurry region depressed along the centreline of the billet by a strong central jet. The temperature gradient in the transition zone is increased, potentially interfering with grain refinement. The cooling rate in the sump is also altered, thereby modifying the dendrite arm spacing of the as-cast billet. The relative position of the sonotrode affects the sump profile, with the sump depth decreased by around 5 mm when the sonotrode is moved above the graphite ring level by 100 mm. The acoustic streaming jet penetrates into the slurry zone and, as a result, the growth direction of dendritic grains in the off-centre position is altered.

The cavitation-induced fragmentation of primary crystals formed in Al alloys were investigated for the first time by high-speed imaging using a novel experimental approach. Three representative primary crystal types, Al3Ti, Si and Al3V with different morphologies and mechanical properties were first extracted by deep etching of the corresponding Al alloys and then subjected to ultrasonic cavitation processing in distilled water. The dynamic interaction between the cavitation bubbles and primary crystals was imaged in situ and in real time. Based on the recorded image sequences, the fragmentation mechanisms of primary crystals were studied. It was found that there are three major mechanisms by which the primary crystals were fragmented by cavitation bubbles. The first one was a slow process via fatigue-type failure. A cyclic pressure exerted by stationary pulsating bubbles caused the propagation of a crack pre-existing in the primary crystal to a critical length which led to fragmentation. The second mechanism was a sudden process due to the collapse of bubbles in a passing cavitation cloud. The pressure produced upon the collapse of the cloud promoted rapid monotonic crack growth and fast fracture in the primary crystals. The third observed mechanism was normal bending fracture as a result of the high pressure arising from the collapse of a bubble cloud and the crack formation at the branch connection points of dendritic primary crystals. The fragmentation of dendrite branches due to the interaction between two freely moving dendritic primary crystals was also observed. A simplified fracture analysis of the observed phenomena was performed. The specific fragmentation mechanism for the primary crystals depended on their morphology and mechanical properties.