Numerical Simulation of Ultrasonic Field During Five-Source Ultrasound-Assisted Casting of 2219 Al Alloy

In this study, the distribution of the acoustic pressure field and cavitation threshold region in Al alloy casting under two five-source ultrasound arrangements (A and B) is investigated, aiming to optimize the five-source ultrasound configuration to improve casting quality. Numerical simulations were conducted using COMSOL software (COMSOL Multiphysics 6.0) to analyze the propagation characteristics of ultrasound in the Al melt and its influence on the cavitation effect under the two arrangements. The simulation results indicate that the cavitation threshold region for arrangement A is slightly larger than that for arrangement B. Furthermore, arrangement A demonstrates superior performance in terms of the uniformity of sound pressure distribution and the reduction in the cavitation threshold. Based on the simulation results, arrangement A was selected for experimental validation. The experimental results reveal that arrangement A, with a radial rod distance (L) of 200 mm from the center point and an insertion depth (H) of 270 mm, significantly refines the grains and improves the distribution of the second phase, thereby confirming the reliability of the simulation results. This study provides a theoretical foundation and practical guidance for the application of five-source ultrasound in Al alloy casting.