The stochastic modeling of solidification structures in alloy 718 remelt ingots

A stochastic numerical approach was developed to model the formation of grain structure and secondary phases during the solidification of nickel-based alloy 718 remelt ingots. The significance of the present stochastic approach is that the simulated phases can be directly compared with actual phases from experiments at two different scales: grain characteristics can be visualized at the macroscale, while the amount, size, and distribution of secondary phases can be viewed at the microscale. The computer becomes a “dynamic metallographic microscope.” Stochastic modeling was applied to simulate the formation of solidification phases (γprimary phase and NbC and eutectic γ-Laves secondary phases) during the solidification of vacuum-arc-remelted and electroslag-remelted alloy 718 ingots. Modeling results, such as pool profile, grain-growth pattern, grain structure (both columnar and equiaxed grains), columnar-to-equiaxed transition, grain size, and secondary dendrite arm spacing, as well as amount, size, and location of both eutectic γ-Laves and NbC phases compared well with experimental data for cast alloy 718. This research demonstrates that the stochastic approaches are relatively fast, comprehensive, and more accurate than the deterministic approaches in predicting the solidification characteristics of remelt ingots and are mature enough to be used effectively by the metal industry for process development and optimization. Laurentiu Nastac earned his Ph.D. in metallurgical and materials engineering at the University of Alabama at Tuscaloosa in 1995. He is currently a senior staff engineer at Concurrent Technologies Corporation. Dr. Nastac is a member of TMS. Suresh Sundarraj earned his Ph.D. in mineral engineering at the University of Minnesota in 1994. He is currently a process modeling engineer for Concurrent Technologies Corporation. Dr. Sundarraj is also a member of TMS. Kuang-O Yu earned his Ph.D. in metallurgical engineering at the University of Kentucky in 1978. He is currently director of research and development at RMI Titanium Company. Dr. Yu is also a member of TMS. Yuan Pang earned his M.S. in mechanical engineering at the University of Akron in 1977. He is currently a principal engineer at Concurrent Technologies Corporation.     

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