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 "title": "Ultrasonic atomization",
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 "excerpt": "Ultrasonic atomization is the ejection of droplets under 10 µm from a liquid surface subjected to ultrasound, used in medical nebulizers, humidifiers, and precision spray coating.",
 "snippet": "Ultrasonic atomization is the ejection of droplets under 10 µm from a liquid surface subjected to ultrasound, used in medical nebulizers, humidifiers, and precision spray coating.",
 "node": "technology.engineering.manufacturing.processes.forming-heat-treatment-and-finishing.solution-and-coating-application-methods",
 "markdown": "# Ultrasonic atomization\n\nUltrasonic atomization is the ejection of fine droplets from a liquid surface or film subjected to ultrasound. It typically produces droplets below 10 µm in diameter with a narrow size distribution at roughly 10% of the energy required for vaporization by heating, and it is used in medical nebulizers, precision spray coating, humidifiers, and metal-powder production.<sup>[1](https://www.sciencedirect.com/science/article/abs/pii/S0894177720307238)</sup><sup> • </sup><sup>[2](https://pmc.ncbi.nlm.nih.gov/articles/PMC8991379/)</sup>\n\n| Key fact | Value |\n|---|---|\n| Droplet size | Typically <10 µm; 7.0 µm from a 484.5 kHz MEMS nozzle; 10–20 µm in 120 kHz spray coating<sup>[2](https://pmc.ncbi.nlm.nih.gov/articles/PMC8991379/)</sup><sup> • </sup><sup>[3](https://engineering.purdue.edu/oxidemems/conferences/ultrasonics2005/DATA/J4J_3.PDF)</sup><sup> • </sup><sup>[4](https://lirias.kuleuven.be/retrieve/3ed0f93c-79be-4ab9-bae3-305a6bbf3fc5)</sup> |\n| Size–frequency relation | \\( d_{p} = 0.34\\,(8\\pi \\cdot \\sigma/(\\rho \\cdot f^{2}))^{1/3} \\); measured constants span \\( \\kappa = 0.17\\text{–}0.65 \\)<sup>[5](https://www.nature.com/articles/s41598-019-42599-8)</sup><sup> • </sup><sup>[1](https://www.sciencedirect.com/science/article/abs/pii/S0894177720307238)</sup> |\n| First report | Wood and Loomis, 1927, quartz oscillators at 0.1–0.7 MHz<sup>[6](https://doi.org/10.1080/14786440908564348)</sup><sup> • </sup><sup>[7](https://pmc.ncbi.nlm.nih.gov/articles/PMC12964042/)</sup> |\n| Typical drive conditions | 36 kHz at 7.5–11.25 W; 1.7 MHz at 30 W; 120 kHz coating nozzle<sup>[1](https://www.sciencedirect.com/science/article/abs/pii/S0894177720307238)</sup><sup> • </sup><sup>[5](https://www.nature.com/articles/s41598-019-42599-8)</sup><sup> • </sup><sup>[4](https://lirias.kuleuven.be/retrieve/3ed0f93c-79be-4ab9-bae3-305a6bbf3fc5)</sup> |\n| Mesh nebulizer output | 0.862 mL/min at 114.7 kHz (simply supported sheet)<sup>[8](https://www.mdpi.com/2076-3417/13/10/6293)</sup> |\n| Energy use | About 10% of the energy of vaporization by heating<sup>[2](https://pmc.ncbi.nlm.nih.gov/articles/PMC8991379/)</sup> |\n| Coating thickness | As low as 30 nm for OLED, solar, and sensor layers<sup>[4](https://lirias.kuleuven.be/retrieve/3ed0f93c-79be-4ab9-bae3-305a6bbf3fc5)</sup> |\n\n## How it works\n\nTwo mechanisms are debated. In the capillary-wave picture, the vibrating surface excites Faraday waves, parametrically driven surface ripples that may be subharmonic (\\( f = F/2 \\)) or harmonic (\\( f = F \\)) depending on the instability and operating conditions; droplets detach from wave crests, so droplet size scales with capillary wavelength.<sup>[5](https://www.nature.com/articles/s41598-019-42599-8)</sup><sup> • </sup><sup>[9](https://pubs.aip.org/asa/jasa/article/130/5/2694/842209/Evidence-of-the-harmonic-Faraday-instability-in)</sup> Lang related the number-median droplet diameter to surface tension \\( \\sigma \\), density \\( \\rho \\), and frequency \\( f \\) by \\( d_{p} = 0.34\\,(8\\pi \\cdot \\sigma/(\\rho \\cdot f^{2}))^{1/3} \\), with the constant \\( \\kappa = 0.34 \\) determined experimentally for 10–800 kHz.<sup>[5](https://www.nature.com/articles/s41598-019-42599-8)</sup><sup> • </sup><sup>[10](https://doi.org/10.1121/1.1909020)</sup><sup> • </sup><sup>[11](https://link.springer.com/article/10.1007/s44187-023-00065-5)</sup> Across nebulizer types spanning nearly two orders of magnitude in frequency, measured constants fall between 0.17 and 0.65, so the relation is approximate rather than universal.<sup>[5](https://www.nature.com/articles/s41598-019-42599-8)</sup>\n\nIn the cavitation picture, acoustically driven bubble oscillations beneath the surface eject droplets. The most accepted theory combines the two: the cavitation-wave hypothesis holds that capillary ripples together with bubble oscillations cause emission.<sup>[12](https://www.cambridge.org/core/journals/journal-of-fluid-mechanics/article/abs/ultrasonic-atomization-of-liquids-in-dropchain-acoustic-fountains/18515174F5524E9790DAEDF0B104B021)</sup> The \"conjunction theory\" couples them explicitly, with periodic hydraulic shocks from cavitation exciting finite-amplitude capillary waves.<sup>[13](https://www.sciencedirect.com/science/article/abs/pii/S0041624X05000983)</sup> Evidence for the bubble role includes atomization thresholds that rise with viscosity, strong suppression under increased static pressure, and a 2024 synchrotron study showing inertial cavitation events puncturing the gas–liquid boundary to produce mist.<sup>[12](https://www.cambridge.org/core/journals/journal-of-fluid-mechanics/article/abs/ultrasonic-atomization-of-liquids-in-dropchain-acoustic-fountains/18515174F5524E9790DAEDF0B104B021)</sup><sup> • </sup><sup>[14](https://www.osti.gov/pages/biblio/2305770)</sup> A 2025 study proposed the sequence \"gas nuclei → acoustic focusing → vibrating bubbles → atomization\", with micro-protrusions on the surface needed for onset.<sup>[7](https://pmc.ncbi.nlm.nih.gov/articles/PMC12964042/)</sup> At MHz frequencies the capillary-wave picture breaks down: at 2.4 MHz, predicted ~2 µm droplets contrast with measured bimodal distributions peaking at 30 nm and 1 µm.<sup>[2](https://pmc.ncbi.nlm.nih.gov/articles/PMC8991379/)</sup>\n\n## How it is done\n\nA system consists of a piezoelectric transducer, often two bonded disks, driven at resonance with a thin liquid layer fed onto the atomization surface, horn, or mesh plate.<sup>[11](https://link.springer.com/article/10.1007/s44187-023-00065-5)</sup> Operating points come from the literature: a 36 kHz atomizer with a 6 × 10⁻⁶ m² irradiating surface driven at 7.5–11.25 W; a commercial mist-maker at 1700 ± 50 kHz and 30 W submerged about 4 cm; and a 20 kHz probe system with 130 W maximum output feeding liquid through a 2.5 mm concentric hole.<sup>[1](https://www.sciencedirect.com/science/article/abs/pii/S0894177720307238)</sup><sup> • </sup><sup>[5](https://www.nature.com/articles/s41598-019-42599-8)</sup><sup> • </sup><sup>[13](https://www.sciencedirect.com/science/article/abs/pii/S0041624X05000983)</sup> Below a critical flow rate no effective atomization occurs, and above it droplets grow because the liquid film on the vibrating surface thickens.<sup>[11](https://link.springer.com/article/10.1007/s44187-023-00065-5)</sup> Horn amplification matters in nozzle designs: a three-stage Fourier horn with per-stage magnification 2 gives a total displacement gain of 8 at the tip.<sup>[15](https://mdpi-res.com/d_attachment/micromachines/micromachines-08-00056/article_deploy/micromachines-08-00056.pdf?version=1487072375)</sup>\n\n## Origin\n\nThe first report of mist from liquid under high-intensity sound waves was published by R.W. Wood and Alfred L. Loomis in 1927 in the Philosophical Magazine, using quartz oscillators at 0.1–0.7 MHz.<sup>[6](https://doi.org/10.1080/14786440908564348)</sup><sup> • </sup><sup>[7](https://pmc.ncbi.nlm.nih.gov/articles/PMC12964042/)</sup> Karl Söllner advanced the cavitation hypothesis of fog formation in 1936 in the Transactions of the Faraday Society.<sup>[16](https://doi.org/10.1039/tf9363201532)</sup> Robert J. Lang presented the capillary-wave hypothesis and a droplet-size relation in the Journal of the [Acoustical Society of America](https://www.edgepedia.org/acoustical-society-of-america) in 1962.<sup>[10](https://doi.org/10.1121/1.1909020)</sup> E.G. Lierke and G. Grießhammer reported ultrasonic atomization of molten metals in Ultrasonics in 1967.<sup>[17](https://doi.org/10.1016/0041-624x%2867%2990066-2)</sup> Later landmarks include the dynamic mesh nebulizer of Naoyoshi Maehara, Sadayuki Ueha, and Eiji Mori (1986),<sup>[18](https://doi.org/10.1063/1.1139006)</sup> MEMS-based multiple-Fourier-horn MHz nozzles by Shirley C. Tsai and colleagues (2006),<sup>[19](https://doi.org/10.1063/1.2161398)</sup> and surface-acoustic-wave atomization by Aisha Qi, Leslie Y. Yeo, and James R. Friend (2008).<sup>[20](https://doi.org/10.1063/1.2953537)</sup>\n\n## Variants\n\n**Fountain atomizers** submerge a transducer below a free surface and atomize the standing fountain; commercial mist-makers run near 1.7 MHz.<sup>[5](https://www.nature.com/articles/s41598-019-42599-8)</sup> **Ultrasonic spray nozzles** feed liquid along a horn to a vibrating tip; commercial bulk-metal nozzles reach 120 kHz with 55 µm peak water droplets, while silicon MEMS nozzles reach 484.5 kHz, atomizing 10–200 µL/min at drive voltages as low as 5.5 V with over 83% of droplets at 7.0 µm and a geometric standard deviation of 1.1.<sup>[3](https://engineering.purdue.edu/oxidemems/conferences/ultrasonics2005/DATA/J4J_3.PDF)</sup> **Vibrating-mesh nebulizers** push liquid through a perforated plate; the dynamic mesh design of Maehara, Ueha, and Mori pumps liquid through a tapered aperture bonded to a PZT ring, with atomization rate proportional to the number of pinholes and peaks of 0.862 mL/min at 114.7 kHz and 0.553 mL/min at 160 kHz under simply supported edges.<sup>[8](https://www.mdpi.com/2076-3417/13/10/6293)</sup><sup> • </sup><sup>[18](https://doi.org/10.1063/1.1139006)</sup> **Surface-acoustic-wave chips** at 9.6 MHz produce micron-sized droplets plus ~50 µm particles, with broad distributions.<sup>[5](https://www.nature.com/articles/s41598-019-42599-8)</sup><sup> • </sup><sup>[20](https://doi.org/10.1063/1.2953537)</sup> **Molten-metal sonotrodes** produce metal powders, demonstrated for aluminum, stainless steel, and titanium alloys.<sup>[17](https://doi.org/10.1016/0041-624x%2867%2990066-2)</sup><sup> • </sup><sup>[21](https://pure.tue.nl/ws/portalfiles/portal/386307191/1-s2.0-S0894177726000518-main.pdf)</sup>\n\n## Applications\n\nAcoustic fountain atomization is the most prevalent variant, with applications in humidifiers, medical nebulizers, spray cooling, thin-film coating, micro/nanopowder synthesis, and fuel combustion.<sup>[7](https://pmc.ncbi.nlm.nih.gov/articles/PMC12964042/)</sup> In electronics, a 120 kHz Sonotek Impact nozzle generates 10–20 µm droplets that deposit coatings as thin as 30 nm for OLEDs, solar panels, and sensors.<sup>[4](https://lirias.kuleuven.be/retrieve/3ed0f93c-79be-4ab9-bae3-305a6bbf3fc5)</sup> In powder metallurgy, ultrasonic atomization of melts yields high-sphericity powders with narrow size distribution for additive manufacturing; particle size decreases with reduced vibration amplitude.<sup>[21](https://pure.tue.nl/ws/portalfiles/portal/386307191/1-s2.0-S0894177726000518-main.pdf)</sup><sup> • </sup><sup>[14](https://www.osti.gov/pages/biblio/2305770)</sup> Recent work includes monodisperse calcium alginate and [PEGDA hydrogel](https://www.edgepedia.org/pegda-hydrogel) microspheres from sharp-tip capillary devices and lipid nanoparticles of ~140 nm from standing-wave spray drying.<sup>[22](https://pubs.rsc.org/en/content/articlehtml/2026/lc/d5lc00954e)</sup><sup> • </sup><sup>[23](https://pubs.rsc.org/en/content/articlelanding/2025/na/d4na01012d)</sup>\n\n## Limitations and alternatives\n\nThroughput is the main constraint. Droplet size rises with flow rate because the feed film thickens; water's Sauter mean diameter increased from 22.1 µm at 0.2 mL/min in a 120 kHz coating nozzle, and below the critical flow rate atomization stops.<sup>[4](https://lirias.kuleuven.be/retrieve/3ed0f93c-79be-4ab9-bae3-305a6bbf3fc5)</sup><sup> • </sup><sup>[11](https://link.springer.com/article/10.1007/s44187-023-00065-5)</sup> This confines ultrasonic atomization to low-flow precision coating rather than bulk spraying. Mesh nebulizers clog with viscous medicines and waste expensive drug in the mesh.<sup>[15](https://mdpi-res.com/d_attachment/micromachines/micromachines-08-00056/article_deploy/micromachines-08-00056.pdf?version=1487072375)</sup> SAWN chips heat the liquid to about 70 °C during prolonged operation, a problem for sensitive formulations, and a glycerol-water solution failed to nebulize at the power that atomized water.<sup>[5](https://www.nature.com/articles/s41598-019-42599-8)</sup> The viscosity effect itself is unsettled: one study found droplet size rising with viscosity up to a threshold then falling, while another found higher viscosity gives smaller, more uniform droplets because capillary-wave growth is reduced and cavitation is weaker; the Rajan and Pandit and Ramisetty correlations even predict opposite directions.<sup>[13](https://www.sciencedirect.com/science/article/abs/pii/S0041624X05000983)</sup><sup> • </sup><sup>[21](https://pure.tue.nl/ws/portalfiles/portal/386307191/1-s2.0-S0894177726000518-main.pdf)</sup><sup> • </sup><sup>[11](https://link.springer.com/article/10.1007/s44187-023-00065-5)</sup> Against pressure and rotary nozzles, the standard food-industry atomizers, ultrasonic devices give better control of droplet size distribution and smaller average droplets, but large-scale ultrasonic spray drying is limited by the economics of scaling the reactors.<sup>[11](https://link.springer.com/article/10.1007/s44187-023-00065-5)</sup> Distribution width depends on operating regime: uniform capillary waves with low cavitation intensity give narrow distributions, while high flow, assisted gas flow, or high-intensity cavitation give bimodal or wide distributions.<sup>[1](https://www.sciencedirect.com/science/article/abs/pii/S0894177720307238)</sup><sup> • </sup><sup>[2](https://pmc.ncbi.nlm.nih.gov/articles/PMC8991379/)</sup>\n\n## References\n\n1. [Investigation of capillary wave, cavitation and droplet diameter distribution during ultrasonic atomization (Experimental Thermal and Fluid Science)](https://www.sciencedirect.com/science/article/abs/pii/S0894177720307238)\n2. [Novel applications of ultrasonic atomization in the manufacturing of fine chemicals, pharmaceuticals, and medical devices (Ultrasonics Sonochemistry)](https://pmc.ncbi.nlm.nih.gov/articles/PMC8991379/)\n3. [Ultrasonic Atomization Using Silicon-Based High-Frequency Multiple-Fourier Horn Nozzles (IEEE Ultrasonics Symposium)](https://engineering.purdue.edu/oxidemems/conferences/ultrasonics2005/DATA/J4J_3.PDF)\n4. [Characterization of Droplet Formation in Ultrasonic Spray Coating: Influence of Ink Formulation Using Phase Doppler Anemometry and Machine Learning](https://lirias.kuleuven.be/retrieve/3ed0f93c-79be-4ab9-bae3-305a6bbf3fc5)\n5. [Size distributions of droplets produced by ultrasonic nebulizers (Scientific Reports, 2019)](https://www.nature.com/articles/s41598-019-42599-8)\n6. [R.W. Wood, Alfred L. Loomis (1927). XXXVIII.The physical and biological effects of high-frequency sound-waves of great intensity. The London Edinburgh and Dublin Philosophical Magazine and Journal of Science.](https://doi.org/10.1080/14786440908564348)\n7. [Role of gas nuclei in ultrasonic atomization in acoustic fountains (2025, PMC)](https://pmc.ncbi.nlm.nih.gov/articles/PMC12964042/)\n8. [Error Correction and Reanalysis of the Vibration Analysis of a Piezoelectric Ultrasonic Atomizer to Control Atomization Rate (Applied Sciences, 2023)](https://www.mdpi.com/2076-3417/13/10/6293)\n9. [Evidence of the harmonic Faraday instability in ultrasonic atomization experiments with a deep, inviscid fluid (J. Acoust. Soc. Am. 130, 2694, 2011)](https://pubs.aip.org/asa/jasa/article/130/5/2694/842209/Evidence-of-the-harmonic-Faraday-instability-in)\n10. [Robert J. Lang (1962). Ultrasonic Atomization of Liquids. The Journal of the Acoustical Society of America.](https://doi.org/10.1121/1.1909020)\n11. [Factors influencing droplet size in pneumatic and ultrasonic atomization and its application in food processing (Discover Food, 2023)](https://link.springer.com/article/10.1007/s44187-023-00065-5)\n12. [Ultrasonic atomization of liquids in drop-chain acoustic fountains (Journal of Fluid Mechanics)](https://www.cambridge.org/core/journals/journal-of-fluid-mechanics/article/abs/ultrasonic-atomization-of-liquids-in-dropchain-acoustic-fountains/18515174F5524E9790DAEDF0B104B021)\n13. [Ultrasonic atomization: Effect of liquid phase properties (Avvaru et al., Ultrasonics)](https://www.sciencedirect.com/science/article/abs/pii/S0041624X05000983)\n14. [New insights into the mechanism of ultrasonic atomization for the production of metal powders in additive manufacturing (Additive Manufacturing, 2024, OSTI record)](https://www.osti.gov/pages/biblio/2305770)\n15. [Faraday Waves-Based Integrated Ultrasonic Micro-Droplet Generator and Applications (Micromachines, MDPI)](https://mdpi-res.com/d_attachment/micromachines/micromachines-08-00056/article_deploy/micromachines-08-00056.pdf?version=1487072375)\n16. [Karl Söllner (1936). The mechanism of the formation of fogs by ultrasonic waves. Transactions of the Faraday Society.](https://doi.org/10.1039/tf9363201532)\n17. [The formation of metal powders by ultrasonic atomization of molten metals (Ultrasonics, 1967)](https://doi.org/10.1016/0041-624x%2867%2990066-2)\n18. [Naoyoshi Maehara, Sadayuki Ueha, Eiji Mori (1986). Influence of the vibrating system of a multipinhole-plate ultrasonic nebulizer on its performance. Review of Scientific Instruments.](https://doi.org/10.1063/1.1139006)\n19. [Shirley C. Tsai and colleagues (2006). Ultrasonic atomization using MHz silicon-based multiple-Fourier horn nozzles. Applied Physics Letters.](https://doi.org/10.1063/1.2161398)\n20. [Aisha Qi, Leslie Y. Yeo, James R. Friend (2008). Interfacial destabilization and atomization driven by surface acoustic waves. Physics of Fluids.](https://doi.org/10.1063/1.2953537)\n21. [Droplet formation in ultrasonic atomization (Experimental Thermal and Fluid Science, TU/e repository copy)](https://pure.tue.nl/ws/portalfiles/portal/386307191/1-s2.0-S0894177726000518-main.pdf)\n22. [Systematic characterization and mechanistic insights into ultrasonically actuated sharp-tip capillary droplet generation (Lab on a Chip, 2026)](https://pubs.rsc.org/en/content/articlehtml/2026/lc/d5lc00954e)\n23. [Microfluidic generation of nanoparticles using standing wave induced ultrasonic spray drying (Nanoscale Advances, 2025)](https://pubs.rsc.org/en/content/articlelanding/2025/na/d4na01012d)\n\n---\n*Topic: Encyclopedia › Technology and the built world › Engineering and manufacturing › Manufacturing processes and fabrication › Forming, heat treatment, and finishing › Solution and coating application methods*\n\n*Initially written Sep 29, 2026 · Edited: Oct 15, 2026; Oct 21, 2026*\n\n*Copyright 2026 EdgeChat AI, a subsidiary of Biostate AI.*\n\nLicense: Edgepedia Community License 1.0, https://www.edgepedia.org/edgepedia/license\n",
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 "credit_html": "\"<a href=\"https://www.edgepedia.org/ultrasonic-atomization\">Ultrasonic atomization</a>\", Edgepedia (EdgeChat), <a href=\"https://www.edgepedia.org/ultrasonic-atomization\">https://www.edgepedia.org/ultrasonic-atomization</a>. <a href=\"https://www.edgepedia.org/edgepedia/license\">Edgepedia Community License 1.0</a>.",
 "speakable": "Ultrasonic atomization is the ejection of droplets under 10 µm from a liquid surface subjected to ultrasound, used in medical nebulizers, humidifiers, and precision spray coating."
}
