Papers by Keyword: Melt Flow

Abstract: The effects of melt flow on dendrite growth during solidification are studied by the quantitative phase field model coupling the Navier-Stokes equations. Through analyzing the relationship between flow velocity and dendrite growth rate in simulations, a flow Péclet number involving with characteristic flow velocity, characteristic length of the zone affected by flow and thermal (solute) diffusion coefficient, is suggested for dendrite growth under convections. The growth rate increment due to flow follows a power-law relationship with the Péclet number. As the Péclet number is much higher than one, the influence of convection on dendrite growth is apparent, whereas as it is below one, the flow effects can be neglected.

Abstract: Cylindrical Pb-Sn alloy samples (diameter: 8 mm, length: 120 mm) of different compositions (30, 40 and 50 wt.% of Sn) were prepared from high pure (4N) components. The unidirectional solidification experiments have been performed according to the upward vertical Bridgman-method by using a rotating magnetic field (RMF) with a magnetic induction of 150 mT and with a frequency of 50 Hz. The sample-movement velocity was constant (0.05 mm/s) and the temperature gradient changed from 7 to 3 K/mm during the solidification process. The first half of samples was solidified without using the magnetic field and the second half was solidified by using the magnetic field. Under the influence of this strong flow induced by the magnetic field, the columnar microstructure of the first part decomposed and a characteristic "Christmas tree"- like macrosegregated structure with equiaxed Pb-dendrites was developed. The secondary dendrite arm spacing (SDAS) and the volume percent of primary Pb-phase (dendrite) were measured by an automatic image analyser on the longitudinal polished sections along the whole length of the samples. The effect of the forced melt flow on the micro-and macrostructure was studied in case of the different sample compositions.

Abstract: This paper provides an analysis of the formation of intermetallic phases in AlSi7Fe1 alloy in samples processed onboard the ISS. Based on axial 2D cross-sections obtained from regions of pure diffusive growth and also solidified with forced melt flow, the sizes and distribution of intermetallic β-Al₅FeSi phases were determined for different solidification velocities. In diffusive case the phases are larger and more homogeneously distributed than in case of induced melt flow. Additionally, especially for lower solidification velocity, the enrichment of Si and Fe in the centre part of the sample results in a few but rather large β-Al₅FeSi particles.

Abstract: Elementary Mn has a great importance as neutralizer of Fe intermetallics like β-Al₅FeSi, which have detrimental effect on mechanical characteristics of AlSi alloys. Presence of Mn in AlSi alloys causes the formation of other intermetallic phases. To understand the effect of solidification conditions and fluid flow on the microstructure of AlSi-based alloys and the addition of Mn leading to Mn-based intermetallics, Al-5 wt pct Si 0.2/0.4/1.0 wt pct Mn alloys have been directionally solidified under defined thermal (gradient 3 K/mm, solidification velocity 0.02-0.12 mm/s) and fluid flow (rotating magnetic field 6 mT) conditions. The primary Al-phase and Mn-based intermetallic phases were studied using 3D X-ray tomography. The spatial morphology of primary phase and intermetallics were characterized with respect to different fluid flow and solidification conditions. The tomography has showed the 3D complicated structure of Mn phases developed.

Abstract: Al–7wt.-% Si–1wt.-% Fe alloy was solidified unidirectionally in the Crystallizer with High Rotating Magnetic Field (CHRMF). The diameter of sample was 8 mm and its length was 120 mm. The parameters of solidification were as follows: solid/liquid interface velocity ~0.082 mm/s, temperature gradient 7+/-1 K/mm, magnetic induction 0 and 150 mT, frequency of magnetic field 0 and 50 Hz. The structure solidified without rotating magnetic field (RMF) showed a homogeneous, columnar dendritic one. The structure solidified by using magnetic stirring showed a dual periodicity. On the one hand, the branches of the “Christmas tree”-like structure known from the earlier experiments contained Al+Si binary eutectic. On the other hand, bands with higher Fe- and Si-content formed in the sample, which were at a larger distance from each other than the branches of the “Christmas tree” structure. The developed microstructure was analyzed by SEM with EDS. The average Si- and Fe-concentrations were measured on the longitudinal section at given places along the length of sample. Furthermore the Si- and the Fe-concentrations close to the bands and among the bands as well as the composition of the compound phases were determined.

Abstract: A measurement of the angular velocity/revolution number of magnetically stirred liquid gallium-indium alloy was realized with newly developed angular velocity measuring equipment. To get additional information about the flow of the melt, a numerical simulation model was performed with ANSYS FLUENT 13.0 with a single phase 2D k-ε turbulence solver. The aim was to reproduce the flow as accurate as possible, so the measured and computed angular velocity data was compared, to see if the system can be modeled fairly well.

Abstract: In this paper, a physical model of semisolid rheo-casting process by cooling sloping plate is established, and the features and parameters of this process are analyzed. The calculation results show that there exists lamellar flow and turbulent flow on the sloping plate surface commonly. The critical transfer distance from lamellar flow to turbulent flow decreases with the increment of the initial flow velocity gradually. The critical transfer distance decreases with the increment of the sloping angle slowly. The effect of the sloping angle on the critical transfer distance is relatively not obvious.

Abstract: A three-dimensional mathematical model has been developed to study turbulent fluid flow, heat transfer and free surface profile in the initial stage of the twin-roll casting strip pool by a commercial software ProCAST. The coupled set of governing equations for mass, momentum and energy balance was solved with the finite element method. The free surface profile of the pool was treated with the Volume of Fluids (VOF) approach. A straight nozzle of metal delivery system has been chosen in the Twin-roll strip casting process. The filling sequences, flow patterns and corresponding temperature profiles in the metal pool of a vertical twin-roll strip casting process were simulated in this study. The calculated results provided a valuable basis for the optimization of process parameters and metal delivery system during the initial pouring stage of twin-roll strip casting.

Abstract: The melt flow has a significant effect on the structure developing during the unidirectional solidification of alloys. This phenomenon can be experienced during the solidification of melts stirred by the rotating magnetic field (RMF)-type magnetohydrodynamic (MHD) facility as well. As it would be very difficult to measure the intensity of melt flow (e.g. its revolution number, angular velocity) during solidification, it seems to be reasonable to perform the so-called "scale model" experiments applied usually in the hydrodynamics. Using the results of these measurements, conclusions can be drawn concerning the flows during solidification by means of the similarity law of hydrodynamics. The revolution number of Ga-In alloy melt placed in the rotating magnetic field can be measured by the equipment developed for performing the "scale model" experiments. The measurements were performed in crucibles with different surface roughness using melt-cylinders with different diameters located in rotating magnetic field having different frequencies and magnetic induction.

Abstract: The objective of this paper is the experimental investigation of the microstructure in Al-6wt%Si-4wt%Cu alloy, directionally solidified without and with forced melt flow, induced by a rotating magnetic field. The flow leads to reduced primary dendrite spacing and to strong radial segregation of silicon and copper. As a consequence the local solidification conditions change, resulting in different types of Al2Cu phase formation. This outcome is explained by ThermoCalc calculations predicting the corresponding solidification behavior.