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Stir casting is a promising technique used for the manufacture of Al-SiC metal matrix composites. The clustering of reinforcement particles is a serious concern in this production method. In this work, mushy-state solidification characteristics in stir casting are numerically simulated using computational fluid dynamics techniques to study the clustering of reinforcement particles.

Effects of process parameters on the distribution of particles are examined by varying stirrer speed, volume fraction of reinforcement, number of blades on stirrer and diameter ratio (ratio of crucible diameter to stirrer diameter). Further, investigation of characteristics of cooling curves during solidification process is carried out. Volume of fluid method in conjunction with a solidification model is used to simulate the multi-phase fluid flow during the mushy-state solidification. Solidification patterns thus obtained clearly indicate a strong influence of process parameters on the distribution of reinforcement particles and solidification time.

From the simulation study, it is observed that increase in stirrer speed from 50 to 150 rad/s promotes faster solidification rate. But, beyond 100 rad/s, stirrer speed limit, clustering of reinforcement particles is observed. The clustering of reinforcement particles is seen when volume fraction of reinforcement is increased beyond 10 per cent. When number of blades on stirrer are increased from three to five, an increase in solidification rate is observed, and an uneven distribution of reinforcement particles are observed for five-blade geometry. It is also seen from the simulation study that a four-blade stirrer gives a better distribution of reinforcement in the molten metal. Decrease in diameter ratio from 2.5 to 1.5 promotes faster solidification rate.

There is 90 per cent closeness in results for simulation study and the published experimental results.

In this work, with a goal to ultimately forward the advancement of additive manufacturing research, the author applies the Wheeler-Boettinger-McFadden model through a progressive series of increasingly complex solidification problems illustrating the evolution of both dendritic as well as columnar growth morphologies. For purposes of convenience, the author assumes idyllic solutions (i.e. the excess energies associated with mixing solid and liquid phases can be neglected).

In this work, the author applied the phase-field model through a progressive series of increasingly complex solidification problems, illustrating the evolution of both dendritic as well as columnar growth morphologies. Beginning with a non-isothermal treatment of pure Ni, the author further examined the isothermal and directional solidification of Cu–Ni binary alloys.

(1) Consistent with previous simulation results, solidification simulations from each of the three cases revealed the presence of parabolic, dendrite tips evolving along directions of maximum interface energy. (2) For pure Ni simulations, changes in the anisotropy and noise magnitudes resulted in an increase of secondary dendritic branches and changes in the direction of propagation. The overall shape of the primary structure tended also to elongate with increased anisotropy. (3) For simulations of isothermal solidification of Ni–Cu binary alloys, the development of primary and secondary dendrite arm formation followed similar patterns associated with a pure substance. Calculations of dendrite tip velocity tended to increase monotonically with increasing anisotropy in accordance with previous research. (4) Simulations of directional solidification of Ni–Cu binary alloys with a linear temperature profile demonstrated the presence of cellular dendrites with relatively weak side-branching. The occurrence of solute trapping was also apparent between the primary dendrite columns. Dendrite tip velocities increased with increasing cooling rate.

This research, particularly the section devoted to directional solidification of binary alloys, describes a novel numerical framework and platform for the parametric analysis of various microstructural related quantities, including the effects due to changes in temperature gradient and cooling rate. Both the evolution of the phase and concentration are resolved.

Free and moving boundary problems require the simultaneous solution of unknown field variables and the boundaries of the domains on which these variables are defined. There are many technologically important processes that lead to moving boundary problems associated with fluid surfaces and solid‐fluid boundaries. These include crystal growth, metal alloy and glass solidification, melting and flame propagation. The directional solidification of semi‐conductor crystals by the Bridgman—Stockbarger method^1,2 is a typical example of such a complex process. A numerical model of this growth method must solve the appropriate heat, mass and momentum transfer equations and determine the location of the melt—solid interface. In this work, a Chebyshev pseudospectral collocation method is adapted to the problem of directional solidification. Implementation involves a solution algorithm that combines domain decomposition, a finite‐difference preconditioned conjugate minimum residual method and a Picard type iterative scheme.

Presents data which relate to the problem of creating a new technique and technology. In the 1990s the problem of the practical use of intermetallids Ni₃Al and Fe₃Al as structural components in aircraft industry in the USSR was at the stage of a pilot application. In the USSR the process of the directional solidification of superalloys used in components of aircraft engines was at a high level. There was a commercial process for obtaining turbine blades with columnar structure (DC) and single crystal structure (SC) using different methods of cooling for the ingots during the growth, such as cooling on the copper shield and in melt metals (Sn,Al). On the basis of obtained data, theoretical research was conducted regarding the creation of new processes which could give rise to the possibility of directional solidification. One of these processes is the method of dosed feeding of the growing ingots. This method allows alterations to the microstructure, the plasticity, the strength of Ni₃Al and Fe₃Al intermetallids, and corrosion and oxidation resistance.

To study the corrosion resistance of the novel alloy Al‐12.6La (wt%) manufactured using directional solidification.

Samples fabricated using the Bridgman growth technique at three different withdrawal velocities were subjected to total immersion tests in distilled water and in 3.5 per cent NaCl solution and to DC polarisation tests in distilled water. XPS analyses conducted on samples after polarisation indicated the presence of an La compound in the non passive corrosion products film formed.

Anodic polarisation induced dissolution of the alloy with the formation of a non passive corrosion product film. During potentiodynamic polarisation, a sudden current increment occurred at a potential value that was more positive for samples solidified at higher rates. The corrosion resistance of this Al‐12.6%La alloy decreased as the solidification rate increased.

The results presented in this work are an insight to the understanding of the corrosion resistance and electrochemical behaviour of this alloy for future engineering applications and development.

The purpose of this paper is to introduce a numerical calculation method to study the uniformity of the magnetic field in a cold crucible used for directional solidification (DS) and provide information for designing a cold crucible that can induce a uniform magnetic field.

To obtain the characteristics of the magnetic field in a cold crucible and its influence on the directional solidification processing, based on experimental verification, 3‐D finite element (FE) models with different crucible configuration‐elements and power parameters were established to study the uniformity of the magnetic field in a cold crucible. In addition, different TiAl ingots were directionally solidified with different cold crucibles, and the solid/liquid (S/L) interfaced were examined to investigate the effect of the magnetic field on the macrostructure of those ingots.

The uniformity of the magnetic field in a given domain can be quantitatively analyzed by statistical methods. Numerical calculation results showed that the uniformity of the magnetic field can be improved by optimizing the crucible configuration and adopting lower frequency. Better uniformity of the magnetic field in a cold crucible is beneficial to directional solidification.

The calculation of the uniformity of the magnetic field is proposed as a method for quantitative study of the distribution characteristics of the magnetic field in a cold crucible. The relationship between the S/L interfaces of TiAl ingots and the uniformity of the magnetic field is initially characterised; additionally, techniques for improving the uniformity of the magnetic field in a cold crucible are suggested.

The purpose of this paper is to present a new numerical approach for modeling the multi‐phase flow during an alloy solidification process. In many solidification processes, advection of solid may have a dramatic effect on bulk convection field as well as on the solid front growth and hence on the macro‐segregation pattern. In the present work, a numerical model is developed to simulate directional solidification in presence of melt convection as well as solid advection in the form of sedimentation. A 2D cavity filled with hyper‐eutectic aqueous ammonium chloride solution (25 wt.% of ammonium chloride) being chilled from one of the side walls has been chosen as the model problem for the numerical simulation.

A fixed grid volume averaging technique has been used for solving mass, momentum, energy, and species equation while taking into account the solid phase advection and local re‐melting. Two different criteria have been identified for the solid particles in the mushy zone to be mobile. These two criteria are represented by a critical solid fraction, and a critical velocity. Based on these two criteria, the mushy zone has been subdivided into two different regions namely, an immobile coherent zone consisting of packed equiaxed crystals and a mobile non‐coherent zone where the solid crystals are able to move.

The numerical results are compared with corresponding experimental observations.

The solid advection velocity and source terms dealing with solid velocity have been calculated using an explicit scheme, whereas the main conservation equations are solved using an implicit scheme.

This paper aims to point out the critical problems in numerical verification of solidification simulation codes and the complexity of the verification and to propose and apply a procedure of generalized verification for macrosegregation simulation.

A partial verification of a finite‐volume computational model of macrosegregation in direct chill (DC) casting of binary aluminum alloys, including the coupled transport phenomena of heat transfer, fluid flow and species transport, is performed. The verification procedure is conducted on numerical test problems, defined as subproblems with respect to the complexity of the physical model, geometry, and boundary conditions. The studied cases are thermal convection with solidification in DC casting, thermal natural convection of a low‐Prandtl‐number liquid metal in a rectangular cavity and 1D directional solidification of a binary Al‐Cu alloy. Grid‐convergence studies, code comparison with an alternative Chebyshev‐collocation method, and comparison with a reference similarity solution are used for verification.

An excellent ability of the model to accurately resolve the thermal convection in the pertinent range of Prandtl and Rayleigh numbers is shown. Concerns regarding the solution of species transport in the mushy zone remain.

The proposed verification procedure is not completed in its entirety. Further verification of the solutal and thermosolutal convection problems is required.

This paper proposes verification techniques for complex coupled solidification problems involving significant convection in the melt.

This paper aims to understand the magnetohydrodynamics (MHD) mechanism in the molten pool under different modes of magnetic field. The comparison focuses on the Lorenz force excitation and its effect on the melt flow and solidification parameters, intending to obtain practical references for the design of magnetic field-assisted laser directed energy deposition (L-DED) equipment.

A three-dimensional transient multi-physical model, coupled with MHD and thermodynamic, was established. The dimension and microstructure of the molten pool under a 0T magnetic field was used as a benchmark for accuracy verification. The interaction between the melt flow and the Lorenz force is compared under a static magnetic field in the X-, Y- and Z-directions, and also an oscillating and alternating magnetic field.

The numerical results indicate that the chaotic fluctuation of melt flow trends to stable under the magnetostatic field, while a periodically oscillating melt flow could be obtained by applying a nonstatic magnetic field. The Y and Z directional applied magnetostatic field shows the effective damping effect, while the two nonstatic magnetic fields discussed in this paper have almost the same effect on melt flow. Since the heat transfer inside the molten pool is dominated by convection, the application of a magnetic field has a limited effect on the temperature gradient and solidification rate at the solidification interface due to the convection mode of melt flow is still Marangoni convection.

This work provided a deeper understanding of the interaction mechanism between the magnetic field and melt flow inside the molten pool, and provided practical references for magnetic field-assisted L-DED equipment design.

The purpose of this paper is to present a 2D numerical simulation of natural convection and phase‐change of succinonitrile in a horizontal Bridgman apparatus. Three different heat transfer mechanisms are specifically studied: no growth, solidification and melting.

The analysis is carried out with a preexisting thermally coupled fixed‐mesh finite element formulation for generalized phase‐change problems.

In the three cases analyzed, the predicted steady‐state liquid‐solid interfaces are found to be highly curved due to the development of a primary shallow cell driven by the imposed furnace temperature gradient. In the no growth case, the heating and cooling jackets remain fixed and, therefore, a stagnant liquid‐solid interface is obtained. On the other hand, the phase transformation in the solidification and melting cases is, respectively, controlled by the forward and backward movement of the jackets. In these last two growth conditions, the permanent regime is characterized by a moving liquid‐solid interface that continuously shifts with the same velocity of the jackets. The numerical results satisfactorily approach the experimental measurements available in the literature.

The numerical simulation of the no growth, solidification and melting cases in a horizontal Bridgman apparatus using a finite element based formulation is the main contribution of this work. This investigation does not only provide consistent results with those previously computed via different numerical techniques for the no growth and solidification conditions but also reports on original numerical predictions for the melting problem. Moreover, all the obtained solid‐liquid interfaces are validated with experimental measurements existing in the literature.