Ultrasonic energy system and method including a ceramic horn
First Claim
1. An acoustic system for applying vibratory energy, the system comprising:
- a horn connected to an ultrasonic energy source, the horn having a length that is other than one half a wavelength of the ultrasonic energy source, wherein at least a leading section and a trailing section of the horn consist essentially of a ceramic material;
wherein the horn is defined by a trailing end and a leading end, and further wherein the ultrasonic energy source includes a mounting component selected from the group consisting of a waveguide and a booster, the trailing end of the horn engaging in an interference fit with the mounting component such that a junction point between the mounting component and the trailing end of the horn is at an anti-node, the horn being secured to the mounting component by a clamping mechanism, wherein the horn is a ceramic cylindrical rod and the mounting component defines a circular bore, wherein the trailing end of the horn is received within the circular bore to provide an interference fit of 0.003 inch at room temperature.
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Abstract
An acoustic system for applying vibratory energy including a horn connected to an ultrasonic energy source. The horn defines an overall length and wavelength, and at least a leading section thereof is comprised of a ceramic material. The leading section has a length of at least ⅛ the horn wavelength. In one preferred embodiment, an entirety of the horn is a ceramic material, and is mounted to a separate component, such as a waveguide, via an interference fit. Regardless, by utilizing a ceramic material for at least a significant portion of the horn, the ultrasonic system of the present invention facilitates long-term operation in extreme environments such as high temperature and/or corrosive fluid mediums. The present invention is useful for fabrication of metal matrix composite wires.
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Citations
10 Claims
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1. An acoustic system for applying vibratory energy, the system comprising:
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a horn connected to an ultrasonic energy source, the horn having a length that is other than one half a wavelength of the ultrasonic energy source, wherein at least a leading section and a trailing section of the horn consist essentially of a ceramic material; wherein the horn is defined by a trailing end and a leading end, and further wherein the ultrasonic energy source includes a mounting component selected from the group consisting of a waveguide and a booster, the trailing end of the horn engaging in an interference fit with the mounting component such that a junction point between the mounting component and the trailing end of the horn is at an anti-node, the horn being secured to the mounting component by a clamping mechanism, wherein the horn is a ceramic cylindrical rod and the mounting component defines a circular bore, wherein the trailing end of the horn is received within the circular bore to provide an interference fit of 0.003 inch at room temperature.
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2. The system of claim 1, wherein the mounting component is a waveguide which has a length selected such that a node is maintained at a mid-span of the waveguide and a mid-span of the horn.
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3. The system of claim 1, wherein the entirety of the horn consists essentially of a ceramic material.
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4. The system of claim 1, wherein the ceramic material includes at least one ceramic selected from silicon nitride, aluminum oxide, sialon, titanium diboride, zirconia, or silicon carbide.
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5. The system of claim 1, wherein the horn is a cylindrical rod.
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6. The system of claim 1, wherein the horn is adapted for at least partial immersion in a high temperature fluid medium.
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7. The system of claim 6, wherein the horn is adapted to transmit ultrasonic energy at a frequency of approximately 20 kHz to a molten metal-based medium and is characterized by a working life of at least 100 hours.
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8. The system of claim 7, wherein the horn is characterized by a working life of at least 200 hours when immersed in a molten aluminum-based medium.
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9. The system of claim 1, wherein the mounting component is a waveguide comprising titanium.
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10. The system of claim 1, further comprising:
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a transducer for changing electrical energy into ultrasonic vibration; and a booster positioned between said transducer and said horn for increasing an amplitude of the vibration; and
wherein the mounting component is a waveguide comprising a material other than ceramic for transferring the amplified vibration to the horn.
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Specification