The transition mode of dilute binary alloys during directional solidification near to the absolute stability limit

The morphological evolution near the absolute stability limit during directional solidification has been studied systematically on dilute Al–Mn alloys. It is found that the interfacial morphology of Al–0.52wt%Mn and Al–1.2wt%Mn alloys changes from coarse cellular structure to fine cells, and then again to be coarsened with the increase of velocity to near the absolute stability limit. This indicates that there exists a minimum cell spacing corresponding to the maximum effective constitutional supercooling. As the growth rate approximates to or exceeds the critical velocity of absolute stability by calculation according to M–S theory, the interfacial morphology of Al–0.52wt%Mn alloy may still retain a cellular structure. For Al–1.2wt%Mn alloy, when the growth velocity is near the absolute stability limit, the fine cells may change to a band or grain-like structure which in some cases takes an oscillating manner, which possibly implies the existence of a non-linear effect during high growth rate.     

Numerical studies on columnar-to-equiaxed transition in directional solidification of binary alloys

A numerical study on columnar-to-equiaxed transition (CET) during directional solidification of binary alloys is presented using a macroscopic solidification model. The position of CET is predicted numerically using a critical cooling rate criterion reported in literature. The macroscopic solidification model takes into account movement of solid phase due to buoyancy, and drag effect on the moving solid phase because of fluid motion. The model is applied to simulate the solidification process for binary alloys (Sn–Pb) and to estimate solidification parameters such as position of the liquidus, velocity of the liquidus isotherm, temperature gradient ahead of the liquidus, and cooling rate at the liquidus. Solidification phenomena under two cooling configurations are studied: one without melt convection and the other involving thermosolutal convection. The numerically predicted positions of CET compare well with those of experiments reported in literature. Melt convection results in higher cooling rate, higher liquidus isotherm velocities, and stimulation of occurrence of CET in comparison to the nonconvecting case. The movement of solid phase aids further the process of CET. With a fixed solid phase, the occurrence of CET based on the same critical cooling rate is delayed and it occurs at a greater distance from the chill.     

The directional solidification of Pb-Sn alloys

Directional solidification experiments have been carried out on different Pb-Sn alloys as a function of temperature gradient G, growth rate V and cooling rate GV. The specimens were solidified under steady state condition with a constant temperature gradient (50 °C/cm) at a wide range of growth rates ((10–400) × 10^–4 cm/s) and with a constant growth rate (17 × 10^–4 cm/s) at a wide range of temperature gradient (10–55 °C/cm). The primary dendrite arm spacing, ₁, and secondary dendrite arm spacing, ₂, were evaluated. This structure parameters were expressed as functions of G, V and GV by using the linear regression analysis. The results were in good agreement with the previous works.     

The solidification characteristics of near rapid and supercooling directional solidification

In the comparison of the solidification characteristics of supercooling directional solidification (SDS) with constrained directional solidification (DS) and with the consideration of the inheritance of supercooled melt, the SDS technique established with the combination of melt supercooling and traditional DS was proposed. An exploring study on SDS techniques was also conducted using appropriate facilities, designed and manufactured by the authors’ laboratory and the deep supercooling of Cu–5.0%Ni alloy, and its DSs were implemented.     

The solidification characteristics of near rapid and supercooling directional solidification

In the comparison of the solidification characteristics of supercooling directional solidification (SDS) with constrained directional solidification (DS) and with the consideration of the inheritance of supercooled melt, the SDS technique established with the combination of melt supercooling and traditional DS was proposed. An exploring study on SDS techniques was also conducted using appropriate facilities, designed and manufactured by the authors’ laboratory and the deep supercooling of Cu–5.0%Ni alloy, and its DSs were implemented.     

Numerical analysis of constitutional supercooling during directional solidification of alloys

Some limitations of Tiller’s morphological stability criterion are discussed in the present study. This criterion assumes a purely diffusive regime in the melt as well as a planar solid–liquid interface and a constant solidification rate. But experimental works in agreement with previous numerical modeling have shown a significant decrease of the growth rate and a variable interface curvature during the concentrated semiconductor alloys solidification. The mathematical expression of the morphological stability criterion was derived by using Tiller’s equation, predicting the solute distribution in the liquid. The numerical computations performed in this study show a significant disagreement between the numerical results and Tiller’s formula. Numerical modeling conducted in conditions when the supercooling should occur, show that the Tiller’s stability criterion cannot predict the moment of interface destabilization. The interface destabilization is numerically observed when some fluctuations appear in the liquid solutal profiles and cause the appearance of a supercooled zone inside the liquid at small distance from the interface. The present numerical results are not in contradiction with the basic elements of the classical constitutional supercooling theory, providing only that the stability criterion cannot predict the moment of the interface destabilization.     

ARTEX — In situ observation of directional solidification of binary aluminium alloys on TEXUS

A binary Al-6wt. % Si alloy was directionally solidified during the TEXUS 39 mission to compare diffusive solidification conditions with convective ones. In addition, the operativeness of a new furnace technology ARTEX using fragile aerogels as a crucible material in microgravity was demonstrated. The TEXUS 39 sample is evaluated with regard to the processing parameters and microstructural features. A reduction of the secondary dendrite arm spacing and spacing of the interdendritic eutectic and an increase of the primary dendrite spacing is observed under microgravity compared with experiments under 1g conditions. To obtain a fundamental understanding of the influence of convections on the microstructure evolution the ARTEX facility is now equipped with a rotating magnetic field device being able to generate a controlled fluid flow in the melt during solidification. The forthcoming flight experiment ofARTEX+ on TEXUS 41 in November 2004 should lead to a direct comparison of pure diffusive growth conditions (TEXUS 39) and controlled convective conditions (TEXUS 41) using the same alloy and also to compare the results with extensive lab research.     

Microstructure evolution in AISI 304 stainless steel during near rapid directional solidification

Abstract

The microstructure evolution of near rapidly directionally solidified AISI 304 stainless steel was investigated in the present paper. It is found that the microstructure consists of δ ferrite dendrites with developed sidebranches and interdendritic austenite (γ) under the temperature gradient (G) of 20 K mm^–1 and growth rate (V) of 1·0 mm s^–1. Coupled growth microstructures of thin lamellar ferrite and austenite begin to form at a higher growth rate of 2·0 mm s^–1. The formation mechanism of the coupled microstructures is analysed based on the nucleation and constitutional undercooling criterion that the δ ferrite phase and austenite phase form alternately before the steady state growth of each phase is reached due to larger undercooling. With further increase of the growth rate up to 3·0 mm s^–1, the morphology of the δ ferrite transforms from lathy to cellular.     

Studies on macrosegregation and double diffusive convection during directional solidification of binary mixture

Abstract

Experimental and numerical studies on macrosegregation during directional solidification of an aqueous ammonium chloride solution in a rectangular cavity are presented. Depending on the initial concentration and boundary temperature conditions, three distinct situations in the liquid during the solidification process are studied: mass diffusion only, solutal convection and double diffusive convection. The time dependent concentration of the solution inside the cavity is measured online for the above three situations using a laser based technique. This technique measures refractive index of the solution, which indirectly gives the concentration variation at a point in the solution during solidification. The interface growth is photographed using a shadowgraph technique, and the flow is visualised using a sheet of laser light scattered by neutrally buoyant, hollow glass spheres seeded in the fluid. Corresponding numerical studies are performed using a macroscopic model based on a fixed grid, enthalpy based, control volume approach. A good agreement between the experimental and computational results is observed.     

Improvement of tensile properties of Al-Si alloys through directional solidification

This study examines the tensile properties in directionally solidified (DS-route) Al-Si alloys and in conventionally die casting (DC-route) of the same composition. An attempt has been made to correlate the results with the fracture and microstructure of the alloys. One of the most important findings in this work is that a marked improvement in ductility is observed for DS samples over their DC-processed counterparts.     

Effect of niobium on the directional solidification and properties of Alnico alloys

The effect of niobium on the extent of columnar growth of grains and on the magnetic properties in Alnico alloys has been studied. Alloys containing 1 % Nb show maximum growth of columnar crystals. In columnar alloys, coercivity increases slowly with increasing niobium content up to 1 %. With further increase in niobium, coercivity and remanence decrease. The maximum energy product (55 kJ m^–3) has been obtained at 1 % Nb. Niobium addition has also been found to suppress the precipitation of the undesirable phase.     

Numerical study on the prediction of microstructure parameters by multi-scale modeling of directional solidification of binary aluminum–silicon alloys

In order to create a model to predict microstructural quantities like grain size, primary and secondary dendrite arm spacing a multi-phase and multi-scale model based on the work of Wang and Beckermann [C. Wang, C. Beckermann, Metallurgical and Materials Transactions A 27A (1996) 2754–2764] was combined with a front tracking technique [A. Wu, A. Ludwig, in: C.-A. Gandin, M. Bellet (Eds.), Modeling of Casting, Welding, and Advanced Solidification Processes – XI, TMS, 2006, pp. 291–298], micro-models for nucleation [M. Rappaz, P. Thevoz, Acta Metallurgica 35 (7) (1987) 1487–1497], primary [J. Hunt, S.-Z. Lu, Metallurgical and Materials Transactions A 27A (1996) 611–623], secondary [W. Kurz, D. Fisher, Fundamentals of Solidification, Trans Tech Publication, 1986, ISBN 0-87849-522-3] dendrite arm spacing and a control volume based finite element solver for axial-symmetric problems. As most of the micro-models are just valid for pure diffusive conditions, the model just takes into account macroscopic diffusion in the melt and thus neglects the influence of melt flow. The new software was used for a comprehensive comparison to several test cases. The validation includes investigation of the correlation of calculated and measured grain size distributions for inoculated alloys. Experimental and numerical data for the primary and secondary dendrite arm spacing for steady state and transient directional solidification were compared in a second step. A good correlation is found for all test cases.     

In-situ observation of solid-liquid interface transition during directional solidification of Al-Zn alloy via X-ray imaging

The morphological instability of solid/liquid(S/L) interface during solidification will result in different patterns of microstructure. In this study, two dimension(2 D) and three dimension(3 D) in-situ observation of solid/liquid interfacial morphology transition in Al-Zn alloy during directional solidification were performed via X-ray imaging. Under a condition of increasing temperature gradient(G), the interface transition from dendritic pattern to cellular pattern, and then to planar growth with perturbation was captured. The effect of solidification parameter(the ratio of temperature gradient and growth velocity(v), G/v) on morphological instabilities was investigated and the experimental results were compared to classical "constitutional supercooling" theory. The results indicate that 2 D and 3 D evolution process of S/L interface morphology under the same thermal condition are different. It seems that the S/L interface in 2 D observation is easier to achieve planar growth than that in 3 D, implying higher S/L interface stability in 2 D thin plate samples. This can be explained as the restricted liquid flow under 2 D solidification which is beneficial to S/L interface stability. The in-situ observation in present study can provide coherent dataset for microstructural formation investigation and related model validation during solidification.     

Effect of rotation on the stability of the melt during the solidification of a binary alloy

Summary Nonlinear solutal convective flow in the melt under a planar solidifying surface and rotating about the vertical axis is investigated in the limit of small segregation. An evolution equation governing the cellular structure of the flow of a binary alloy is derived. This equation incorporates convective instabilities and rotational effects. The presence of rotation can inhibit the onset of the cellular structure by effectively magnifying the segregation.     

Al-Pb合金快速定向凝固的数值模拟

在考虑凝固界面前沿第二相液滴形核、长大以及迁移综合作用的基础上 ,提出了描述偏晶合金在快速定向凝固条件下微观组织形成过程的数学模型 ,并对Al-Pb轴承合金在垂直Bridgeman定向凝固条件下的凝固组织进化过程进行了计算分析 .结果表明 :在大的凝固速度条件下 ,凝固界面前沿存在成分过冷区 ,液 -液相分解在此区域内进行 ;在恒定的温度梯度条件下 ,凝固速度越快 ,第二相液滴的形核速率越大 ,液滴的数量密度越高 ,平均半径越小 ;凝固界面前沿液滴的平均半径 (R)与凝固速度 (v)之间存在如下指数关系 :R(z =0 ) =C2 v-0 .3 9± 0 .0 1     

Pr对Sn-Cd包晶合金定向凝固组织的影响

为了解Pr对Sn-Cd包晶合金凝固组织的作用,在不同抽拉速率下对Sn-Cd-Pr合金进行定向凝固实验.采用光学显微镜、扫描电子显微镜(SEM)和能谱分析(EDS)研究了Pr对Sn-Cd包晶合金凝固组织的影响.研究发现:对于Sn-1.8%Cd过包晶合金,在2μm/s时0.5%的Pr增加了包晶相β的体积分数;在4μm/s时凝固组织明显细化.对于Sn-0.65%Cd亚包晶合金,在4μm/s时Pr的加入促进了平→胞界面的转变;在16μm/s时随着Pr含量的增大,凝固组织逐渐细化;在100μm/s时Pr含量的增大使凝固组织仅有微弱的细化.研究表明,Pr的加入可以改变组成相的体积分数、细化组织以及减小界面稳定性.     

Coarsening during solidification of aluminium-copper alloys

Coarsening of directionally solidified -phase dendrites and of particulate -phase/liquid mixtures was investigated in Al-4, 10 and 20 wt% Cu alloys, as a function of temperature, composition and presence or absence of forced convection. Isothermal dendritic coarsening in the absence of convection operated in two stages. In stage I the dendritic structure broke down through remelting into fragments which spheroidized quickly; in stage II the spherical particles coarsened slowly. The coarsening rate of the dendritic or particulate solid increased with temperature and copper dilution. Alloy inoculation with titanium slowed coarsening, yielding finer dendritic microstructures. The effect of turbulent flow on coarsening was manifested only for longer holding times. At higher impeller angular velocities the dendritic structure breaks down into fragments which spheroidize rapidly. At lower shear rates (below 650 rev min^–1) solid particles in solid-liquid mixtures coalesce into clusters, whereas at higher rates the clusters break up again into individual particles. A coarsening model was introduced which showed that coarsening is faster in the presence of forced convection, because of the resulting decrease in solute diffusion-boundary layer thickness.     

The effect of a magnetic field upon directional solidification of Sn-Cd and Sn-Pb alloys

Eutectic alloys of Sn-Cd and Sn-Pb were solidified vertically under a transverse magnetic field of 23000 Oe. Analysis of the data indicated that the magnetic field had no effect upon the lamellar spacing of the eutectic or the orientation of the lamellae relative to the magnetic field. This result indicates that the effect of the magnetic field upon the liquid diffusion coefficient is too small in these systems to allow control of lamellar spacing by means of an applied magnetic field.     

Evolution of the microstructure and solute distribution of Sn-10wt% Bi alloys during electromagnetic field-assisted directional solidification

The effects of forced flows at different velocities on microstructure and solute distribution during the directional solidification of Sn-10 wt% Bi alloys under a simultaneous imposition of a transverse static magnetic field(TSMF) and an external direct current(DC) have been investigated experimentally and numerically. The experimental results show that the solid-liquid interface will gradually become sloping with the increase of the forced flow velocity when the thermoelectric magnetic convection(TEMC)dominates the forced flow at solidification front. However, the interface will gradually become planar as the flow velocity further increases when the electromagnetic convection(EMC) dominates the forced flow. Moreover, when the flow velocity gradually increases, the primary dendrite spacing decreases from384 to 105 μm accordingly. The simulation results show that the solute distribution at the two sides of the sample can be significantly changed by the forced flow at solidification front. The rejected solute will be unidirectionally transported to one side of the sample along the TEMC(a low-velocity forced flow),thereby causing the formation of a sloping interface. However, the rejected solute will be returned back along the EMC(a higher-velocity force flow), which results in a planar interface. Furthermore, the solute content at the two sides of the sample under the forced flows at different velocities was measured. The results are in good agreement with the simulation results, which shows that the solute content difference between the two sides of the sample reaches the maximum when a 0.5 T TSMF is applied, while the solute content difference decreases to zero with a simultaneous application of a 0.5 T TSMF and a 1.6 × 10~5 A/m~2 external DC.     

Dynamics of directional coarsening in binary alloys: Monte-Carlo simulation

Directional coarsening in binary alloys during phase separation has been simulated by means of the Monte-Carlo technique based on the spin-exchange Ising model in two-dimensional squared lattices. A uniaxial interaction has been imposed on the Hamiltonian of the standard Ising system in order to achieve directional coarsening of the domained structure. Characterization of the domained structure with the snapshot patterns, the spatial correlation function and the structure function, is also given. It has been found that with time this system exhibits highly uniaxially anisotropic patterns of the domain morphology and the correlation function, and also achieves a uniaxially textured structure function. Under such a uniaxially anisotropic interaction, the dynamics of the system still achieves a good agreement with the dynamic scaling hypothesis. Towards the later stage, the kinetics of coarsening acquires a growth exponent of 1/3, the same as the well-known value in the isotropic alloys. This revised version was published online in November 2006 with corrections to the Cover Date.