Ultrasonic atomization is increasingly used in industry; however, the lack of corresponding theoretical studies on the atomization mechanism and performance effects has led to a lack of scientific application. In this study, multiple Faraday waves in ultrasonic atomization were simulated and a comparative study of Faraday instability theory was conducted in conjunction with experiments. For the inviscid case, the parametric curve equations explain the excitation and competition mechanisms of different frequency harmonics. The position of the parameter pair determines whether the perturbation of the Faraday wave is linear or not. The surface perturbation displacements of Faraday waves are plotted from theoretical, experimental, and simulation perspectives, respectively, and the three agree well. Different parameters correspond to different parameter curve positions and maximum perturbation growth rates, which determine the intensity of the Faraday instability and thus cause changes in the atomization characteristics. In the viscous case, the Faraday instability depends on the wave number and viscosity, and the intensity of the instability can be obtained from the instability threshold. All the theoretical predictions in this study are validated by experiments and simulations, which can provide scientific guidance for process optimization of practical ultrasonic atomization production.

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• Capillary waves
• Flow instability
• Surface tension effects
• Thin fluid films