Work

Simulation-based optimization of ultrasonic horns for improved ultrasonic melt treatment in magnesium nanocomposite stir casting

Year: 2026

Type: article

Abstract: Ultrasonic melt treatment (UMT) is an effective complementary technique for reducing casting defects and improving product quality in the stir casting of magnesium based nanocomposites. However, its effectiveness at elevated temperatures is significantly limited by severe acoustic attenuation, particularly due to thermal detuning-induced resonant frequency drift of the ultrasonic horn. This study presents simulation-based design and optimization of nine ultrasonic horns with stepped, conical, and arcuate profiles, made of Ti-6Al-4V, Monel K-500, and C103 niobium alloys, for UMT applications at high temperatures. Modal, harmonic, and thermomechanical analyses were performed using COMSOL Multiphysics at room temperature and at 700 °C. The results showed that, with increasing temperature, the resonant frequency decreases significantly and the amplification factor increases. Titanium horns exhibited the most stable performance. The optimized titanium horn was fabricated and implemented in a UMT system for ultrasonic-assisted stir casting. Introducing 20 kHz vibration for 10 minutes at 700 °C into the ZK60-Al2O3 melt reduced porosity by 46.3% and increased density by 3.8% compared with the non-UMT sample, confirming the effectiveness of the designed horn in improving melt quality.

Source: Results in Engineering

DOI: 10.1016/j.rineng.2026.109759

Authors: Saeid Shahraki, Amir Yazdian, Alireza Sadeghi, Karen Abrinia

Institutions: University of Tehran, Tarbiat Modares University

Language: English

Topic: Aluminum Alloys Composites Properties

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

Open Access status: gold

Estimated APC paid: $1,940

Funder: Iran National Science Foundation