Mushy-Zone Rayleigh Number to Describe Macrosegregation and Channel Segregate Formation During Directional Solidification of Metallic Alloys

A recently defined mushy-zone Rayleigh number (R-aM) that includes side-branching contributions to the mushy-zone permeability has been examined for its correlation with the longitudinal macrosegregation and channel segregate formation. The Rayleigh number shows (1) a strong correlation between the extent of longitudinal macrosegregation and increase in the mushy-zone convection and (2) a good ability to predict the formation of channel segregates during directional solidification

Mushy Zone Morphology During Directional Solidification of Pb-5.8 Wt Pct Sb Alloy

The Pb-5.8 wt pet Sb alloy was directionally solidified with a positive thermal gradient of 140 K cm(-1) at a growth speed ranging from 0.8 to 30 mu m s(-1), and then it was quenched to retain the mushy zone morphology. The morphology of the mushy zone along its entire length has been characterized by using a serial sectioning and three-dimensional image reconstruction technique. Variation in the cellular/dendritic shape factor, hydraulic radius of the interdendritic region, and fraction solid along the mushy zone length has been studied. A comparison with predictions from theoretical models indicates that convection remarkably reduces the primary dendrite spacing while its influence on the dendrite tip radius is not as significant

Macrosegregation During Dendritic Arrayed Growth of Hypoeutectic Pb-Sn Alloys: Influence of Primary Arm Spacing and Mushy Zone Length

Thermosolutal convection in the dendritic mushy zone occurs during directional solidification of hypoeutectic lead tin alloys in a positive thermal gradient, with the melt on the top and the solid below. This results in macrosegregation along the length of the solidified samples. The extent of macrosegregation increases with increasing primary dendrite spacings for constant mushy zone length. For constant primary spacings, the macrosegregation increases with decreasing mushy zone length. Presence of convection reduces the primary dendrite spacings. However, convection in the interdendritic melt has significantly more influence on the spacings as compared with that in the overlying melt, which is caused by the solutal buildup at the dendrite tips

Effect of Magnetic-Field on the Microstructure and Macrosegregation in Directionally Solidified Pb-Sn Alloys

An investigation into the influence of a transverse magnetic field (0.45 T) on the mushy zone morphology and macrosegregation in directionally solidified hypoeutectic Pb-Sn alloy shows that the field has no influence on the morphology of dendritic arrays. The field does, however, cause severe distortion in the cellular array morphology. Cellular arrayed growth with the magnetic field results in an extensive channel formation in the mushy zone, as opposed to the well-aligned and uniformly distributed cells formed in the absence of the field. The channels are produced due to the anisotropy in the thermosolutal convection caused by the magnetic field. Macrosegregation, however, along the length of the directionally solidified samples is not influenced by this magnetic field for either the cellular or dendritic arrays

Primary Dendrite Distribution and Disorder During Directional Solidification of Pb-Sb Alloys

Pb-2.2 wt pct Sb and Pb-5.8 wt pet Sb alloys have been directionally solidified from a single-crystal seed with its [100] orientation parallel to the growth direction, to examine the primary dendrite distribution and disorder of the dendrite arrays. The dendrite distribution and ordering have been investigated using analysis techniques such as the Gauss-amplitude fit to the frequency distribution of nearest and higher-order spacings, minimum spanning tree (MST), Voronoi polygon, and Fourier transform (FT) of the dendrite centers. Since the arrangement of dendrites is driven by the requirement to accommodate side-branch growth along the (100) directions, the FT images of the fully developed dendrite centers contain spots which indicate this preferred alignment. A directional solidification distance of about three mushy-zone lengths is sufficient to ensure a steady-state dendritic array, in terms of reaching a constant mean primary spacing. However, local dendrite ordering continues throughout the directional solidification process. The interdendritic convection not only decreases the mean primary spacing, it also makes the dendrite array more disordered and reduces the ratio of the upper and lower spacing limits, as defined by the largest 5 pct and the smallest 5 pct of the population

Pattern formation in directional solidification under shear flow. I: Linear stability analysis and basic patterns

An asymptotic interface equation for directional solidification near the absolute stabiliy limit is extended by a nonlocal term describing a shear flow parallel to the interface. In the long-wave limit considered, the flow acts destabilizing on a planar interface. Moreover, linear stability analysis suggests that the morphology diagram is modified by the flow near the onset of the Mullins-Sekerka instability. Via numerical analysis, the bifurcation structure of the system is shown to change. Besides the known hexagonal cells, structures consisting of stripes arise. Due to its symmetry-breaking properties, the flow term induces a lateral drift of the whole pattern, once the instability has become active. The drift velocity is measured numerically and described analytically in the framework of a linear analysis. At large flow strength, the linear description breaks down, which is accompanied by a transition to flow-dominated morphologies, described in a companion paper. Small and intermediate flows lead to increased order in the lattice structure of the pattern, facilitating the elimination of defects. Locally oscillating structures appear closer to the instability threshold with flow than without.Comment: 20 pages, Latex, accepted for Physical Review

The Effect of Convection on Disorder in Primary Cellular and Dendritic Arrays

Directional solidification studies have been carried out to characterize the spatial disorder in the arrays of cells and dendrites. Different factors that cause array disorder are investigated experimentally and analyzed numerically. In addition to the disorder resulting from the fundamental selection of a range of primary spacings under given experimental conditions, a significant variation in primary spacings is shown to occur in bulk samples due to convection effects, especially at low growth velocities. The effect of convection on array disorder is examined through directional solidification studies in two different alloy systems, Pb-Sn and Al-Cu. A detailed analysis of the spacing distribution is carried out, which shows that the disorder in the spacing distribution is greater in the Al-Cu system than in Pb-Sn system. Numerical models are developed which show that fluid motion can occur in both these systems due to the negative axial density gradient or due the radial temperature gradient which is always present in Bridgman growth. The modes of convection have been found to be significantly different in these systems, due to the solute being heavier than the solvent in the Al-Cu system and lighter than it in the Pb-Sn system. The results of the model have been shown to explain experimental observations of higher disorder and greater solute segregation in a weakly convective Al-Cu system than those in a highly convective Pb-Sn system

Comparative study of the Columnar-Equiaxed Transition in microgravity and on ground during directional solidification of a refined Al - 3.5 wt% Ni alloy

A comparative analysis of directional solidification experiments performed on a refined Al - 3.5 wt% Ni alloy in microgravity (facility AGHF, STS95 mission, Nov. 98 ; facility TITUS, MIR-PERSEUS mission, May-June 99) and on ground is presented here. The objective is to separate the respective influence of growth rate and natural convection on the formation of dendritic microstructures in the columnar/equiaxed transition range. Local segregations observed both in µg and on ground in transient regions along the solidification direction are discussed. Ground reference experiments, which were performed vertically upwards i.e. in a solutally stabilizing configuration, show increasing radial macrosegregation at decreasing low growth rates, resulting from a local thermosolutal flow pattern, which is characteristic of this configuration. In microgravity, equiaxed microstructures are observed at all the investigated rates, a specific dendritic morphology being obtained at the lowest rate where the equiaxed grain size is the largest. By contrast, the ground experiments present transitions from purely columnar to mixed columnarequiaxed and purely equiaxed structures for increasing rates

Directional solidification of refined Al–3.5wt% Ni under natural convection and under a forced flow driven by a travelling magnetic field

International audienceA new Bridgman-type furnace has been designed and built.This furnace has two specific items: a device conceived to minimise any residual radial thermal gradient near the solid–liquid interface (induced by the difference in thermal conductivities between liquid and solid), and a travelling magnetic field to drive a forced flow in the liquid above the solidifying interface. We have already performed comparative experiments of directional solidification on refined and non-refined Al-based alloys, under natural convection and under forced flow, controlled by the travelling magnetic field. We will present some characteristics of this new furnace, and the preliminary results obtained by solidifying refined Al–3.5 wt% Ni, with and without the travelling magnetic field