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Development of New Ultrasonicaly Assisted Processes in Metallurgy a nd Machinery.

Objective


Foreseen Results

Ultrasonic generators in the frequency range 25 - 40 kHz with a power up to 1 kW for piezoelectric transducer and with a power up to 10 kW for a magnetostrictive transducer will be developed and built up.
Magnetostrictive transducers from new Fe-Al-Cr alloys with powers of 1 and 3 kW will be designed.
Devices for the measurement of the displacement amplitude, acoustic power, acoustic pressure and level of cavitation noise in liquids and level of alternative stresses and strains in solids will be developed.
The effective methods of ultrasonic transmission to the solidifying melt will be developed.
The methods of ultrasonic transmission to solid metals during impact surface treatment and drawing of titanium wire will be optimized.
The data of basic research accumulated allow to expect with confidence that ultrasonics can be used to solve a lot of technical and scientific problems. In metallurgy the high power ultrasonics might be used for refining of metal melts and structural refinement of ingots. In machinery ultrasonics might be used for impact treatment of metal surfaces. At the solid/solid interface, ultrasonic vibrations change the metal structure, surface conditions, reduce the friction and accelerate the diffusion processes.
The long term industrial objectives associated with the proposed project are development of the following technologies based on the accurate measurement of the acoustic parameters in the system "transducer - waveguide system- load" which can be transferred to different applications.

Development of the ultrasonic grain refinement methods for aluminium alloys at casting processes.
Development of the ultrasonic treatment for surface hardening and post stress relief.
Optimization of the process of wire drawing.

For these purposes a special ultrasonic equipment and technology should be developed. It is very important that the main components of ultrasonic systems (generator, transducer, and the system for the control of the acoustic parameters) will be identical for possible applications in metallurgy and machinery. Only the working tool influencing directly on the technological process should be different. In frame of the project it is planned to design a new model of ultrasonic computerized generator with a power up to 10 kW in the frequency range 25 - 40 kHz, which could be used for different technologies. It is planned to develop two magnetostrictive transducer of a power of I and 3 kW. The method of calculation for the optimized size and shape of the magnetostrictive transducer, which takes into account the properties of the material in strong magnetic fields, will be used. The devices for the measurement of the displacement amplitude; acoustic power, acoustic pressure and level of cavitation noise in liquid melts and the level of alternative stresses and strains in solids will be developed.

The use of ultrasonics will result in shorter process times, lower energy requirements, and better product quality. It is possible to integrate new ultrasonic technologies with established manufacturing processes.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

UNIVERSITAET STUTTGART
Address
75,Seestraße 75
70174 Stuttgart
Germany

Participants (4)

Academy of Sciences of Belarus
Belarus
Address
13,Ludnikov Avenue 13
210717 Vitebsk
Centre of Applied Acoustics
Russia
Address
31,Leninski Prospect 31
117907 Moscow
Rolls Royce plc
United Kingdom
Address
Moor Lane
DE24 8BJ Derby
Ukrainian Academy of Sciences
Ukraine
Address
36,Vernadsky Blvd. 36
252142 Kiev