来流对Al-Cu合金三维树枝晶生长的影响

建立了模拟二元合金树枝晶生长的三维元胞自动机模型,以Al-4%Cu(质量分数)为模型合金,模拟了合金过冷熔体中树枝晶的生长过程,研究了来流对枝晶生长的影响.结果表明,来流对合金过冷熔体中三维树枝晶生长影响显著,迎流侧枝晶尖端生长速度随来流速度的增大而增大,枝晶尖端半径随来流速度的增大而减小;随着来流速度的增大,枝晶尖端选择参数减小;在给定过冷度条件下,随界面能各向异性的增大,来流对枝晶尖端选择参数的影响增强;对于给定的合金(或界面能各向异性),来流对枝晶尖端选择参数的影响随着过冷度的增大而增强.     

Effect of melt flow on dendritic growth in AlSi7-based alloys during directional solidification

Abstract

High-strength automotive components are often made of AlSi7-based alloys. A very challenging problem with aluminium casting is the influence of melt flow during solidification, because it affects the microstructure formation and therefore the material properties. The scope of this paper is to investigate the effect of forced melt flow on the evolution of the dendritic microstructure in a binary AlSi7 alloy during directional solidification. Global modelling using the software CrysMAS provides typical flow patterns and velocities. These values are used as boundary condition for the flow in the phase field code MICRESS, which allows the numerical simulation of dendritic array solidification in 2D with applied flow. From solidification experiments in a gradient furnace with applied rotating magnetic field the dendrite shapes are determined. It is found consistently that intense melt flow leads to asymmetric dendrite shapes and the growth behaviour of the dendrite arms is directly correlated with the flow direction.     

Lattice Boltzmann modeling of dendritic growth in a forced melt convection

A two-dimensional (2D) lattice Boltzmann-based model is developed to simulate solutal dendritic growth of binary alloys in the presence of forced flow. The model adopts the lattice Boltzmann method (LBM) that describes transport phenomena by the evolution of distribution functions of moving pseudoparticles to numerically solve fluid flow and solute transport governed by both convection and diffusion. Based on the LBM-calculated solutal field, the dynamics of dendritic growth is determined according to a previously proposed local solutal equilibrium approach. After detailed model analysis and validation, the model is applied to simulate single and equiaxed multidendritic growth of Al–Cu alloys with forced convection. The results demonstrate the quantitative, numerically stable and computationally efficient capabilities of the proposed model. It is found that the solute distribution and dendritic growth are strongly influenced by convection, producing asymmetrical dendrites that grow faster in the upstream direction, but mostly slower in the downstream direction.     

Modelling of dendritic growth under forced convection in solidification of Al–7Si alloy

Abstract

An integrated microscale model is used to describe the dendritic growth morphology of Al–7Si alloy under forced convection, which combines the two-dimensional finite difference method (FDM) with the cellular automaton (CA) model. The FDM is used to simulate the induced fluid flow and solute transfer. The CA model is used to depict the dendritic morphology. Simulations are performed to investigate the influences of processing variables on morphological evolution under stirring. Calculated results reveal that at the intermediate undercooling, the growth morphology changes from dendritic to rosette as the rotation speed increases. The dendritic growth is promoted by increasing the undercooling. The rotation speed has a minor influence on microstructure formation for the cases of lower and higher undercoolings. A globulitic structure is formed as the nucleation density is increased. Changing the rotation speed is found to have a negligible influence on morphological evolution for the grain refined alloy.     

Melt flow in a mushy zone – barrier effect of intermetallic phases

Abstract

Iron and manganese are common impurity elements in cast aluminium alloys, especially in secondary aluminium. During casting Fe/Mn-containing intermetallics are formed between the aluminium dendrites, which cause porosity and shrinkage defects. In this paper an experimental study on the influence of controlled convection during solidification on the spatial arrangement of intermetallic phases and their interaction with the dendritic microstructure in Al–7Si–1Fe (AlSiFe) and Al–7Si–1Mn (AlSiMn) alloys (wt-%) is presented. Forced convection is induced by a rotating magnetic field. The alloys are solidified directionally over a range of constant solidification velocities (0·015–0·18 mm s^–1) at a constant temperature gradient G of 3 K mm^–1. The results indicate that the primary spacing and the secondary dendrite arm spacing are affected by the presence of Fe and Mn intermetallic phases. In samples solidified under forced convections the primary dendrite arm spacing did not depend on the solidification velocity and no obvious fluid flow effect on the secondary spacing could be detected. These observations are in contrast to Fe and Mn free alloys. It seems that the intermetallics act as a barrier for the flow into the mushy zone.     

Simulation of dendritic growth of magnesium alloys with fluid flow

Fluid flow has a significant impact on the microstructure evolution of alloys during solidification. Based on the previous work relating simulation of the dendritic growth of magnesium alloys with hcp (hexagonal close-packed) structure, an extension was made to the formerly established CA (cellular automaton) model with the purpose of studying the effect of fluid flow on the dendritic growth of magnesium alloys. The modified projection method was used to solve the transport equations of flow field. By coupling the flow field with the solute field, simulation results of equiaxed and columnar dendritic growth of magnesium alloys with fluid flow were achieved. The simulated results were quantitatively compared with those without fluid flow. Moreover, a comparison was also made between the present work and previous works conducted by others. It can be concluded that a deep understanding of the dendritic growth of magnesium alloys with fluid flow can be obtained by applying the present numerical model.     

Simulation of dendritic growth of magnesium al oys with fluid flow

Fluid flow has a significant impact on the microstructure evolution of alloys during solidification. Based on the previous work relating simulation of the dendritic growth of magnesium alloys with hcp(hexagonal closepacked) structure, an extension was made to the formerly established CA(cellular automaton) model with the purpose of studying the effect of fluid flow on the dendritic growth of magnesium alloys. The modified projection method was used to solve the transport equations of flow field. By coupling the flow field with the solute field, simulation results of equiaxed and columnar dendritic growth of magnesium alloys with fluid flow were achieved. The simulated results were quantitatively compared with those without fluid flow. Moreover, a comparison was also made between the present work and previous works conducted by others. It can be concluded that a deep understanding of the dendritic growth of magnesium alloys with fluid flow can be obtained by applying the present numerical model.     

Effects of magnetic fields on crystal growth

Abstract

The effects of a constant uniform magnetic field on thermoelectric currents during dendritic solidification were investigated using a two-dimensional enthalpy based numerical model. Using an approximation for three-dimensional unconstricted growth, the resulting Lorentz forces generate a circulating flow influencing the solidification pattern. Under the presence of a strong magnetic field secondary growth on the clockwise side of the primary arm of the dendrite was encouraged, whereas the anticlockwise side is suppressed due to a reduction in local free energy. The preferred direction of growth rotated in the clockwise sense under an anticlockwise flow. The tip velocity is significantly increased compared with growth in stagnant flow. This is due to a small recirculation at the tip of the dendrite; bringing in colder liquid and lowering the concentration of solute.     

Macrosegregation in directionally solidified dendritic alloys

In this article, gravity-driven flow and its subsequent effect of promoting macrosegregation during unidirectional solidification of dendritic alloys is presented. Examples of macrosegregation that arise during the controlled directional solidification of hypo- and hypereutectic Pb−Sn alloys are shown, and a method of preventing macrosegregation is demonstrated. The experimental work is discussed in terms of how current knowledge of solute redistribution in a dendritic array can be promoted as well as how the processing technique might be applied to improve microstructural homogeneity during controlled directional solidification. Authors' Note: Excellent sources for historical information are Cyril Stanley Smith's booksA Search for Structure, A History of Metallography, andThe Science of Steel 1532–1786. We acknowledge that there were many early investigations regarding segregation phenomena that took place in countries other than the United States and Great Britain that have not been referenced. Furthermore, conference proceedings and reports are not included (e.g., prior to 1938, the British Iron and Steel Institute published seven reports on the heterogeneity of stel ingots). In trying to keep the discussion within the context of dendritic growth we do not, unfortunately, recognize the many important crystal growth/planar/cellular front investigations. Finally, there are certainly many recent and relevant contributions of which we are unaware and apologize for the lack of their inclusion. R.N. Grugel earned his Ph.D. in metallurgical engineering at Michigan Technological University in 1983. He is currently a staff scientist at the Universities Space Research Association. He is also a member of TMS. L.N. Brush earned his Ph.D. in metallurgical engineering and materials science at Carnegie Mellon University in 1988. He is currently associate professor at the University of Washington.     

Numerical modelling of 3D plastic flow and heat transfer during friction stir welding of stainless steel

Abstract

Three-dimensional (3D) viscoplastic flow and temperature field during friction stir welding (FSW) of 304 austenitic stainless steel were mathematically modelled. The equations of conservation of mass, momentum and energy were solved in three dimensions using spatially variable thermophysical properties using a methodology adapted from well established previous work in fusion welding. Non-Newtonian viscosity for the metal flow was calculated considering strain rate and temperature dependent flow stress. The computed profiles of strain rate and viscosity were examined in light of the existing literature on thermomechanical processing of alloys. The computed results showed significant viscoplastic flow near the tool surface, and convective transport of heat was found to be an important mechanism of heat transfer. The computed temperature and velocity fields demonstrated strongly 3D nature of the transport of heat and mass indicating the need for 3D calculations. The computed temperature profiles agreed well with the corresponding experimentally measured values. The non-Newtonian viscosity for FSW of stainless steel was found to be of the same order of magnitude as that for the FSW of aluminium. Like FSW of aluminium, the viscosity was found to be a strong function of both strain rate and temperature, while strain rate was found to be the most dominant factor. A small region of recirculating plasticised material was found to be present near the tool pin. The size of this region was larger near the shoulder and smaller further away from it. Streamlines around the pin were influenced by the presence of the rotating shoulder, especially at higher elevations. Stream lines indicated that material was transported mainly around the pin in the retreating side.     

Morphological development of solidification structures under forced fluid flow: a Monte-Carlo simulation

A Monte-Carlo simulation of microstructural development under forced convection is presented. The model takes into account both diffusive and forced fluid flow, kinetics of atomic attachment at the solid–liquid interface and structural modification under the influence of capillary forces. It has been shown that the nature of fluid flow has a very significant influence on the morphology of the solidification structure. A laminar type flow is shown to destabilize the solid–liquid interface promoting dendritic growth for solid growing from fixed substrate. Particle rotation under streamlined flow, or a periodic change in the fluid flow direction around the growing solid is, however, shown to produce the rosette type solidification morphology. A turbulent type flow penetrating into the interdendritic region produces fine and compact solidification structures with or without liquid entrapment.     

EBSD characterisation and modelling of columnar dendritic grains growing in the presence of fluid flow

Columnar dendritic grains of steel grown in the presence of fluid flow (e.g. solidified on turning rolls) have been characterised by Electron Backscattered Diffraction (EBSD) technique. It is shown that grains have a random crystallographic orientation at the surfaces of the sheet in contact with the mould. In the middle of the sheet, the grains which have survived the growth selection mechanisms exhibit a 〈100〉 texture in which the average dendrite trunk direction is not exactly aligned with the thermal gradient (i.e. the normal to the surfaces of the sheet). It is tilted by about 15° toward the upstream direction. This deviation is examined by simulations of grain structure formation based on a three-dimensional Cellular Automaton (CA)–Finite Element (FE) (3D CAFE) model, which has been modified in order to account for fluid flow effects. The modified CA algorithm includes a growth kinetics of the dendrites which is a function of both the undercooling and fluid flow direction. It is validated by comparing the predicted shape of an individual grain growing under given thermal and fluid flow conditions with an analytical solution. The 3D CAFE predictions of the columnar grains grown in the presence of fluid flow are in good agreement with the experimental EBSD results.     

Effects of electromagnetic stirring on microstructures of solidified aluminum alloys

1　INTRODUCTIONPractically ,mechanicalstirringandelectromag neticstirring (EMS)arewidelyusedtogenerateforcedflowinsolidificationandcastingofmetalsandalloys,resultingin greatchangesofthesolidifiedstructures,segregationsand propertiesofthecast ings .Muchattentionhasbeenpaidtosolidificationofdendriticalloyssuperposedwithforcedflow ,andmanypreviousworkshavebeenfocusedontheeffectsoffluidflowonthestructuraltransitions,suchascolumnar equiaxedtransitions(CET)ormacro segre gationinthealloys[13] .…     

Free dendritic growth model considering both interfacial nonisothermal nature and effect of convection for binary alloy

Considering both the effect of the nonisothermal nature of the interface as well as the effect of forced convection, an extended free dendritic growth model for binary alloys was proposed. Comparative analysis indicates that the effect of convection on solute diffusion is more remarkable compared with the ignorable effect of convection on thermal diffusion at low bath undercooling, due to the fact that solute diffusion coefficient is usually three orders of magnitude less than thermal diffusion coefficient. At high bath undercooling, the effect of convection on the dendritic growth is very slight. Furthermore, a satisfying agreement between the model predictions with the available experiment data for the Cu₇₀Ni₃₀ alloy was obtained, especially at low bath undercoolings, profiting from the higher values of interfacial migration velocity predicted by the present model with nonideal fluid case than that predicted by the one ignoring the effect of convection.     

Observation of dendritic growth and fragmentation in Ga–In alloys by X-ray radioscopy

Abstract

Capabilities of the X-ray attenuation contrast radioscopy were utilised to provide a real time diagnostic technique for observations of dendritic growth and fragmentation during solidification of a Ga–30In (wt-%) alloy. The solidification process was visualised by means of a microfocus X-ray tube providing shadow radiographs at spatial resolutions of about 10 μm. Experiments have been carried out to solidify the Ga–In alloy unidirectionally either starting from the bottom or the top of the specimen. The first case is significantly affected by solutal convection, which governs a redistribution of solute concentration. A detachment of dendrite side arms, which is unambiguously caused by melt flow, was not observed. Dendritic fragmentation occurs during the solidification in the reverse top down direction. Variations of the applied cooling rate excited a transition from a columnar to an equiaxed dendritic growth (CET).     

Geometrical and Mathematical Modelling of Running Systems

Abstract

In the running and gating of metal alloys, the first stage of pouring is the most critical. This is because the fluid flow conditions which exist in the early stages of pouring can control the quality of the casting. Sound castings are the result of the combined effect of both correct fluid flow and correct heat transfer during casting. The aim of this paper is to investigate fluid flow behaviour of molten metals in a horizontally-parted system. Studies of the moving aluminium liquid front suggest that the free height of the advancing stream is a function of liquid velocity, surface tension and density. Equations to correlate these properties have been derived and verified against experimental results. Proposals for the design of pouring basin, sprue and runner for high quality cast products are presented.     

Variational methods for microstructural-evolution theories

Recent progress in variational methods helps to provide general principles for microstructural evolution. Especially when several processes are interacting, such general principles are useful to formulate dynamical equations and to specify rules for evolution processes. Variational methods provide new insight and apply even under conditions of nonlinearity, nondifferentiability, and extreme anisotropy. Central to them is the concept of gradient flow with respect to an inner product. This article shows, through examples, that both well-known kinetic equations and new triple junctions motions fit in this context. W. Craig Carter earned his Ph.D. in materials science at the University of California at Berkeley in 1989. He is currently a research scientist at the National Institute of Standards and Technology. J.E. Taylor earned her Ph.D. in mathematics at Princeton University in 1973. She is currently a professor at Rutgers University. J.W. Cahn earned his Ph.D. in chemistry at the University of California at Berkeley in 1952. He is currently a metallurgist at the National Institute of Standards and Technology. Dr. Cahn is also a fellow of TMS.     

Thermal fluid dynamics of liquid bridge transfer in laser wire deposition 3D printing

ABSTRACT

Liquid bridge transfer mode is most favourable deposition pattern in laser wire deposition. However, the thermal fluid dynamics has not been well understood. In this paper, we systematically investigated the fluid dynamics during liquid bridge transfer in the printing process. We developed a novel three-dimensional heat transfer and fluid flow model by considering the effect of wire feeding. The results showed that for typical process parameters the Weber number (We) of the fluid on the liquid bridge is on the order of O(10⁰～10¹). A dimensionless slenderness number (Sl), was roughly estimated at the range of 3.17～4.57 for maintaining the liquid bridge. This study provides the fluid mechanics insights of the metal transfer mechanisms in 3D printing process.     

Deflection of columnar grains during solidification of aluminium alloys under forced flow conditions

Abstract

Fluid flow strongly influences the grain morphology promoting growth of the columnar structure deflected towards the incoming flow. The effects of forced flow and initial superheat on columnar grain deflection of aluminium alloys were experimentally investigated in this work. The computer simulations of the flow with solidification included previously validated against experimental temperature measurements were used to interpret experimental results. It is shown that the deflection degree strongly depends on the inlet velocity, melt superheat, and alloy composition. Generally, the deflection angle increases with accelerated flow and at a higher superheat. Some quantitative correlations are obtained. Furthermore, several factors affecting the deflection of the grains are discussed.     

Simulation of electromagnetic-flow fields in Mg melt under pulsed magnetic field

The effects of a pulsed magnetic field on the solidified microstructure of pure Mg were investigated.The results show that microstructure of pure Mg is considerably refined via columnar-to-equiaxed growth under the pulsed magnetic field and the average grain size is refined to 260μm under the optimal processing conditions.A mathematical model was built to describe the interaction of the electromagnetic-flow fields during solidification with ANSYS software.The pulsed electric circuit was first solved and the...