Highlights
Providing a new method for the preparation of Al-Ti-C grain refiner.
The contact angle θ of aluminum-carbon interface is reduced under ultrasonic field.
TiC particles are detached from the interface driven by sound pressure, which results that the wetting interface is updated in real time.
The wetting and spreading of the aluminum melt on the graphite surface under ultrasonic field are simulated.
Al and Al-5Ti alloys were manufactured by an ultrasonic casting method with a new device, and their ultrasonic cavitation erosion behaviors of Al and Al-5Ti alloys in the distilled water were clarified. The damage mechanism was analyzed by macro photograph, scanning electronic micrograph and three-dimensional morphology, and the results demonstrate that Al-5Ti alloys have better cavitation erosion resistance than Al in terms of the mass loss and the surface damage. The deformation mechanism of Al and Al-5Ti alloys under cavitation erosion is mainly dislocation slip, and the Al3Ti phase enhances the cavitation erosion resistance of Al-5Ti alloys. In addition, the maximum depth of cavitation pits in the Al-5Ti sample is less than that in the Al sample for 31.3%.
Two kinds of Ti-alloys, i.e., Al–5Ti and Al–10Ti alloys, were manufactured in this study, and their ultrasonic cavitation erosion behaviors in 3.5 wt.% NaCl solution were evaluated by the cumulative mass loss, scanning electronic micrograph, and three-dimensional morphology. The results show that mass loss and surface damage of the Al, Al–5Ti, and Al–10Ti alloys obviously increased with the increasing cavitation erosion time. Compared with the pure Al, the cavitation resistance of the Al–5Ti and Al–10Ti alloys was improved because of the presence of the TiAl3 phase. In addition, the synergistic effect between cavitation and corrosion of the Al–Ti alloy in 3.5 wt.% NaCl solution was studied according to the polarization curve of the moving electrode. The mass loss caused by the synergistic effect between cavitation erosion and corrosion accounted for a large percentage, 23.59%, indicating that corrosion has a critical impact on the cavitation erosion of the Al–Ti alloys. Compared with corrosion promoted by cavitation erosion, the cavitation erosion promoted by corrosion had a larger promoting effect.
A key technical problem in the preparation of Al-Ti-C grain refiner and other composite materials is the poor wetting of the Al-C interface, which greatly restricts the development of the preparation technology of related composite materials. In view of this scientific challenge, a novel ultrasonic field wetting angle measuring instrument has been designed to research the wetting behavior of the liquid–solid interface and ensure that preparation conditions are optimized. The dimensional parameters of the ultrasonic transducer and the horn in the novel ultrasonic wetting angle measuring instrument have been designed by theoretical calculation, and the modal analysis was performed for the ultrasonic horn using the functions of displacement and time. Modal analysis was utilized to optimize the dimension of the ultrasonic horn, and the natural frequency of the longitudinal vibration of the horn was reduced from 22,130 Hz to 22,013 Hz, resulting in an error rate between the actual value (22,013 Hz) and the design value (20 kHz) of less than 1%. In addition, the influence of different transition arc radiuses on the maximum stress of the optimized ultrasonic horn was analyzed.
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