Modelling of Resonant Acoustic Mixing Parameters

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Traditionally, multi-material blended components are mixed inplanetary mixers, cast to blocks/blanks, and undergo subtractivemachining to form shaped components. Composites such assyntactics and highly filled resin based systems are blended in rotarydrums and other conventional blade based mixers over long periodsof time, decanted, moulded to blocks and again undergo subtractivemachining. These are both time consuming, wasteful and potentiallyhazardous when working with energetically-sensitive materials.Resonant Acoustic Mixing (RAM) is a novel powder/powder,powder/fluid and fluid/fluid mixing technology that has the potentialto directly mix materials into the final net (or near net) componentshape without further processing, removing or significantly reducingmaterial waste, time and hazards. RAM is being trialled with adefence contractor and is showing excellent results to-date. However,modelling of this mixing technique is in its infancy and has not beenaddressed and thus, cannot be said to be optimised. Numerous mixing(intensity, time, pressure temperature), material (particle size, shape,pre-blending, order of addition) and tooling (shape, composition,mixing head space) parameters impact the efficiency of RAM andthus if modelled would add significant value in optimising the mixingprocess.Modelling and/or trials would improve understanding of thecapability, both limitations and opportunities. A phase space ofmixing sweet-spots could be identified, further de-risking potentialprocessing operations by avoiding knife-edge scenarios. Once mixed,the blend of powders still needs to be decanted to a mouldtool. Thispresents a more controlled flowing environment but can lead to phaseseparation layering and other forms of de mixing especially when considering particles of different size or density.