An adjustable acoustic metamaterial cell using a magnetic membrane for tunable resonance.

Acoustic metamaterials are growing in popularity for sound applications including noise control. Despite this, there remain significant challenges associated with the fabrication of these materials for the sub-100 Hz regime, because acoustic metamaterials for such frequencies typically require sub-mm scale features to control sound waves. Advances in additive manufacturing technologies have provided practical methods for rapid fabrication of acoustic metamaterials. However, there is a relatively high sensitivity of their resonant characteristics to sub-mm deviations in geometry, pushing the limits of additive manufacturing. One way of overcoming this is via active control of device resonance. Here, an acoustic metamaterial cell with adjustable resonance is demonstrated for the sub-100 Hz regime. A functionally superparamagnetic membrane-devised to facilitate the fabrication process by eliminating magnetic poling requirements-is engineered using stereolithography, and its mechanical and acoustic properties are experimentally measured using laser Doppler vibrometry and electret microphone testing, with a mathematical model developed to predict the cell response. It is demonstrated that an adjustable magnetic acoustic metamaterial can be fabricated at ultra-subwavelength dimensions ( ≤ λ /77.5), exhibiting adjustable resonance from 88.73 to 86.63 Hz. It is anticipated that this research will drive new innovations in adjustable metamaterials, including wider frequency ranges.

A mechanistic study identifying improved technology critical metal delamination from printed circuit boards at lower power sonications in a deep eutectic solvent.

Deep eutectic solvents (DESs) are an emerging class of ionic liquids that offer a solution to reclaiming technology critical metals (TCMs) from electronic waste, with potential for improved life cycle analysis. The high viscosities typical of DESs, however, impose mass transport limitations such that passive TCM removal generally requires immersion over extended durations, in some cases in the order of hours. It is postulated that, through the targeted application of power ultrasound, delamination of key structures in electronic components immersed in DESs can be significantly accelerated, thereby enabling rapid recovery of TCMs. In this paper, we fully characterise cavitation in a Choline Chloride-Ethylene Glycol DES as a function of sonotrode input power, by the acoustic detection of the bubble collapse shockwave content generated during sonications at more than 20 input powers over the available range. This justifies the selection of two powers for a detailed study of ultrasonically enhanced TCM-delamination from printed circuit boards (PCBs). Dual-perspective high-speed imaging is employed, which facilitates simultaneous observation of TCM removal, and the cavitation evolution and interaction with the PCB surface. Bubble jetting is identified as a key contributor to initial pitting of the TCM layers, exposing the larger underlying copper layer, with the contributions of additional inertial cavitation-mediated phenomena such as bubble-collapse shockwaves also demonstrated as important for delamination. Optimal cavitation activity throughout the sonication then promotes etching of the copper base layer of the PCB structure targeted by the DES, liberating the overlaying TCMs in sections as large as 0.79 mm2. We report a thirtyfold improvement in processing time compared to passive delamination, with sonications at the lower power outperforming those at the higher power. The results demonstrate the potential for industrially scalable recovery of TCMs from the growing quantities of global e-waste, using combined power ultrasonics and DESs.

Additive Manufacture of Small-Scale Metamaterial Structures for Acoustic and Ultrasonic Applications.

Acoustic metamaterials are large-scale materials with small-scale structures. These structures allow for unusual interaction with propagating sound and endow the large-scale material with exceptional acoustic properties not found in normal materials. However, their multi-scale nature means that the manufacture of these materials is not trivial, often requiring micron-scale resolution over centimetre length scales. In this review, we bring together a variety of acoustic metamaterial designs and separately discuss ways to create them using the latest trends in additive manufacturing. We highlight the advantages and disadvantages of different techniques that act as barriers towards the development of realisable acoustic metamaterials for practical audio and ultrasonic applications and speculate on potential future developments.

Flow Velocity Measurement Using a Spatial Averaging Method with Two-Dimensional Flexural Ultrasonic Array Technology.

Accurate average flow velocity determination is essential for flow measurement in many industries, including automotive, chemical, and oil and gas. The ultrasonic transit-time method is common for average flow velocity measurement, but current limitations restrict measurement accuracy, including fluid dynamic effects from unavoidable phenomena such as turbulence, swirls or vortices, and systematic flow meter errors in calibration or configuration. A new spatial averaging method is proposed, based on flexural ultrasonic array transducer technology, to improve measurement accuracy and reduce the uncertainty of the measurement results. A novel two-dimensional flexural ultrasonic array transducer is developed to validate this measurement method, comprising eight individual elements, each forming distinct paths to a single ultrasonic transducer. These paths are distributed in two chordal planes, symmetric and adjacent to a diametral plane. It is demonstrated that the root-mean-square deviation of the average flow velocity, computed using the spatial averaging method with the array transducer is 2.94%, which is lower compared to that of the individual paths ranging from 3.65% to 8.87% with an average of 6.90%. This is advantageous for improving the accuracy and reducing the uncertainty of classical single-path ultrasonic flow meters, and also for conventional multi-path ultrasonic flow meters through the measurement via each flow plane with reduced uncertainty. This research will drive new developments in ultrasonic flow measurement in a wide range of industrial applications.

The Influence of Air Pressure on the Dynamics of Flexural Ultrasonic Transducers.

The flexural ultrasonic transducer comprises a piezoelectric ceramic disc bonded to a membrane. The vibrations of the piezoelectric ceramic disc induce flexural modes in the membrane, producing ultrasound waves. The transducer is principally utilized for proximity or flow measurement, designed for operation at atmospheric pressure conditions. However, there is rapidly growing industrial demand for the flexural ultrasonic transducer in applications including water metering or in petrochemical plants where the pressure levels of the gas or liquid environment can approach 100 bar. In this study, characterization methods including electrical impedance analysis and pitch-catch ultrasound measurement are employed to demonstrate the dynamic performance of flexural ultrasonic transducers in air at elevated pressures approaching 100 bar. Measurement principles are discussed, in addition to modifications to the transducer design for ensuring resilience at increasing air pressure levels. The results highlight the importance of controlling the parameters of the measurement environment and show that although the conventional design of flexural ultrasonic transducer can exhibit functionality towards 100 bar, its dynamic performance is unsuitable for accurate ultrasound measurement. It is anticipated that this research will initiate new developments in ultrasound measurement systems for fluid environments at elevated pressures.

A Comparison of Two Configurations for a Dual-Resonance Cymbal Transducer.

The ability to design tuned ultrasonic devices that can be operated in the same mode at two different frequencies has the potential to benefit a range of applications, such as surgical cutting procedures where the penetration through soft then hard tissues could be enhanced by switching the operating frequency. The cymbal transducer has recently been adapted to form a prototype ultrasonic surgical cutting device that operates at a single frequency. In this paper, two different methods of configuring a dual-resonance cymbal transducer are detailed. The first approach relies on transducer fabrication using different metals for the two endcaps, thereby forming a dual-resonance transducer. The second employs transducer endcaps composed from a shape memory alloy, superelastic Nitinol. The resonance frequency of the Nitinol transducer depends on the phase microstructure of the material, switchable through the temperature or stress dependence of the Nitinol endcaps. The vibration response of each transducer is measured through electrical impedance measurements and laser Doppler vibrometry, and finite-element analysis is used to show the sensitivity of transducer modal response to the fabrication processes. Through this paper, two viable dual-resonance cymbal transducers are designed and characterized and compared to illustrate the advantages and disadvantages of the two different approaches.

The Dynamic Performance of Flexural Ultrasonic Transducers.

Flexural ultrasonic transducers are principally used as proximity sensors and for industrial metrology. Their operation relies on a piezoelectric ceramic to generate a flexing of a metallic membrane, which delivers the ultrasound signal. The performance of flexural ultrasonic transducers has been largely limited to excitation through a short voltage burst signal at a designated mechanical resonance frequency. However, a steady-state amplitude response is not generated instantaneously in a flexural ultrasonic transducer from a drive excitation signal, and differences in the drive characteristics between transmitting and receiving transducers can affect the measured response. This research investigates the dynamic performance of flexural ultrasonic transducers using acoustic microphone measurements and laser Doppler vibrometry, supported by a detailed mechanical analog model, in a process which has not before been applied to the flexural ultrasonic transducer. These techniques are employed to gain insights into the physics of their vibration behaviour, vital for the optimisation of industrial ultrasound systems.

Ultrasonic compaction of granular geological materials.

It has been shown that the compaction of granular materials for applications such as pharmaceutical tableting and plastic moulding can be enhanced by ultrasonic vibration of the compaction die. Ultrasonic vibrations can reduce the compaction pressure and increase particle fusion, leading to higher strength products. In this paper, the potential benefits of ultrasonics in the compaction of geological granular materials in downhole applications are explored, to gain insight into the effects of ultrasonic vibrations on compaction of different materials commonly encountered in sub-sea drilling. Ultrasonic vibrations are applied, using a resonant 20kHz compactor, to the compaction of loose sand and drill waste cuttings derived from oolitic limestone, clean quartz sandstone, and slate-phyllite. For each material, a higher strain for a given compaction pressure was achieved, with higher sample density compared to that in the case of an absence of ultrasonics. The relationships between the operational parameters of ultrasonic vibration amplitude and true strain rate are explored and shown to be dependent on the physical characteristics of the compacting materials.

An ultrasonic orthopaedic surgical device based on a cymbal transducer.

An ultrasonic orthopaedic surgical device is presented, where the ultrasonic actuation relies on a modification of the classical cymbal transducer. All current devices consist of a Langevin ultrasonic transducer with a tuned cutting blade attached, where resonance is required to provide sufficient vibrational amplitude to cut bone. However, this requirement restricts the geometry and offers little opportunity to propose miniaturised devices or complex blades. The class V flextensional cymbal transducer is proposed here as the basis for a new design, where the cymbal delivers the required vibrational amplitude, and the design of the attached cutting insert can be tailored for the required cut. Consequently, the device can be optimised to deliver an accurate and precise cutting capability. A prototype device is presented, based on the cymbal configuration and designed to operate at 25.5kHz with a displacement amplitude of 30µm at 300V. Measurements of vibrational and impedance responses elucidate the mechanical and electrical characteristics of the device. Subsequent cutting tests on rat femur demonstrate device performance consistent with a commercial Langevin-based ultrasonic device and show that cutting is achieved using less electrical power and a lower piezoceramic volume. Histological analysis exhibits a higher proportion of live cells in the region around the cut site for the cymbal device than for a powered sagittal or a manual saw, demonstrating the potential for the ultrasonic device to result in faster healing.

Smart cymbal transducers with nitinol end caps tunable to multiple operating frequencies.

Cymbal flextensional transducers have principally been adopted for sensing and actuation and their performance in higher power applications has only recently been investigated. Nitinol is a shape-memory alloy (SMA) with excellent strain recovery, durability, corrosion resistance, and fatigue strength. Although it has been incorporated in many applications, the implementation of nitinol, or any of the SMAs, in power ultrasonic applications is limited. Nitinol exhibits two phenomena, the first being the superelastic effect and the second being the shape-memory effect (SME). This paper assesses two cymbal transducers, one assembled with superelastic nitinol end caps and the other with shape-memory nitinol end caps. Characterization of the nitinol alloy before the design of such transducers is vital, so that they can be tuned to the desired operating frequencies. It is shown this can be achieved for shape-memory nitinol using differential scanning calorimetry (DSC); however, it is also shown that characterizing superelastic nitinol with DSC is problematic. Two transducers are assembled whose two operating frequencies can be tuned, and their dynamic behaviors are compared. Both transducers are shown to be tunable, with limitation for high-power applications largely being associated with the bond layer.