Study of thermoelectric magnetohydrodynamic convection on solute redistribution during laser additive manufacturing

Melt pools formed in laser additive manufacturing (AM) are subject to large thermal gradients, resulting in the formation of thermoelectric currents due to the Seebeck effect. When in the presence of an external magnetic field, a Lorentz force is formed which drives fluid flow in the melt pool. This Thermoelectric Magnetohydrodynamics (TEMHD) phenomenon, can have a significant impact on the melt pool morphology and can alter the microstructural evolution of the solidification process. By coupling steady-state mesoscopic melt pool calculations to a microscopic solidification model, predictions of the resulting microstructure for multiple deposited layers have been obtained. The results indicate that the magnetic field can have a transformative effect on the microstructure and solute redistribution. This study highlights the theoretical potential for using magnetic fields as an additional control system to tailor AM microstructures

Contactless ultrasonic treatment in direct chill casting

Uniformity of composition and grain refinement are desirable traits in the direct chill (DC) casting of non-ferrous alloy ingots. Ultrasonic treatment (UST) is a proven method for achieving grain refinement, with uniformity of composition achieved with additional melt stirring. The immersed sonotrode technique has been employed for this purpose to treat alloys both within the launder prior to DC casting, and directly in the sump. In both cases mixing is weak, relying on buoyancy driven flow or in the latter case on acoustic streaming. In this work we consider an alternative electromagnetic (EM) technique used directly in the caster, inducing ultrasonic vibrations coupled to strong melt stirring. This ‘contactless sonotrode’ technique relies on a kilohertz frequency induction coil lowered towards the melt with the frequency tuned to reach acoustic resonance within the melt pool. The technique developed with a combination of numerical models and physical experiments has been successfully used in batch to refine the microstructure and degas aluminum in a crucible. In this work we extend the numerical model, coupling electromagnetics, fluid flow, gas cavitation, heat transfer and solidification to examine the feasibility of use in the DC process. Simulations show that a consistent resonant mode is obtainable within a vigorously mixed melt pool, with high pressure regions at the Blake threshold required for cavitation localized to the liquidus temperature. It is assumed extreme conditions in the mushy zone due to cavitation would promote dendrite fragmentation and that, coupled with strong stirring, would lead to fine equiaxed grains

Thermoelectric magnetohydrodynamic control of melt pool dynamics and microstructure evolution in additive manufacturing

Large thermal gradients in the melt pool from rapid heating followed by rapid cooling in metal additive manufacturing generate large thermoelectric currents. Applying an external magnetic field to the process introduces fluid flow through thermoelectric magnetohydrodynamics. Convective transport of heat and mass can then modify the melt pool dynamics and alter microstructural evolution. As a novel technique, this shows great promise in controlling the process to improve quality and mitigate defect formation. However, there is very little knowledge within the scientific community on the fundamental principles of this physical phenomenon to support practical implementation. To address this multiphysics problem that couples the key phenomena of melting/solidification, electromagnetism, hydrodynamics, heat and mass transport, the lattice Boltzmann method for fluid dynamics was combined with a purpose-built code addressing solidification modelling and electromagnetics. The theoretical study presented here investigates the hydrodynamic mechanisms introduced by the magnetic field. The resulting steady-state solutions of modified melt pool shapes and thermal fields are then used to predict the microstructure evolution using a cellular automata based grain growth model. The results clearly demonstrate that the hydrodynamic mechanisms and, therefore, microstructure characteristics are strongly dependent on magnetic field orientation

Acoustic resonance for contactless ultrasonic cavitation in alloy melts

Contactless ultrasound is a novel, easily implemented, technique for the Ultrasonic Treatment (UST) of liquid metals. Instead of using a vibrating sonotrode probe inside the melt, which leads to contamination, we consider a high AC frequency electromagnetic coil placed close to the metal free surface. The coil induces a rapidly changing Lorentz force, which in turn excites sound waves. To reach the necessary pressure amplitude for cavitation with the minimum electrical energy use, it was found necessary to achieve acoustic resonance in the liquid volume, by finely tuning the coil AC supply frequency. The appearance of cavitation was then detected experimentally with an externally placed ultrasonic microphone and confirmed by the reduction in grain size of the solidified metal. To predict the appearance of various resonant modes numerically, the exact dimensions of the melt volume, the holding crucible, surrounding structures and their sound properties are required. As cavitation progresses the speed of sound in the melt changes, which in practice means resonance becomes intermittent. Given the complexity of the situation, two competing numerical models are used to compute the soundfield. A high order time-domain method focusing on a particular forcing frequency and a Helmholtz frequency domain method scanning the full frequency range of the power supply. A good agreement is achieved between the two methods and experiments which means the optimal setup for the process can be predicted with some accuracy

Modulating Meltpool Dynamics and Microstructure using Thermoelectric Magnetohydrodynamics in Additive Manufacturing

Meltpool modulation in Selective Laser Remelting Additive Manufacturing via an oscillating magnetic field generates Thermoelectric Magnetohydrodynamics (TEMHD) flow. Numerical predictions show that the resulting microstructure can be significantly altered. A multi-scale numerical model captures the meso-scale melt pool dynamics coupled to microscale solidification showing the microstructure evolution and solute redistribution. The results highlight the complex interaction of the various physical phenomena and also show the method's potential to disrupt the epitaxial growth defect. The model predictions are supported by preliminary experimental results that demonstrate the dependency of the melt pool depth on magnetic field orientation. The results highlight how a time-dependent field has the potential to provide an independent control mechanism to tailor microstructures

Progress in the development of a contactless ultrasonic processing route for alloy grain refinement

A high frequency tuned electromagnetic (EM) induction coil can be used to induce ultrasonic pressure waves leading to gas cavitation in alloy melts. This is a useful ‘contactless’ approach compared to the usual immersed sonotrode technique. One then expects the same benefits obtained in the traditional ultrasonic treatment (UST) of melts, such as degassing, microstructure refinement and dispersion of particles. However, such an approach avoids melt contamination due to probe erosion prevalent in immersed sonotrodes and it has the potential to be used on higher temperature and reactive alloys. Induction stirring due to the Lorentz force produced by the coil is an added benefit, allowing for the treatment of large melt volumes, a current limitation of UST systems. At ultrasonic frequencies (> 20 kHz), due to the ‘skin effect’ electromagnetic forces vibrate just a thin volume by the surface of the metal facing the induction source. These vibrations are transmitted as acoustic pressure waves into the bulk and to achieve sufficient fluctuation amplitudes for cavitation, acoustic resonance is sought by carefully adjusting the generator frequency. This is akin to the tuning of a musical instrument, where the geometry and sound properties of the metal, crucible and surrounding structure play an important part. In terms of modelling, this is a multi-physics system, since fluid flow with heat transfer and phase change are coupled to electromagnetic and acoustic fields. The various models used and their coupling are explained in this paper, together with the various complications arising by the physics of cavitation. Experimental validation is obtained on a prototype rig featuring a conical induction coil inserted into the melting crucible containing the various alloys being examined. When resonance is reached, measurements demonstrate strong stirring, evidence of cavitation and finally grain refinement

Numerical modelling of the ultrasonic treatment of aluminium melts: An overview of recent advances

The prediction of the acoustic pressure field and associated streaming is of paramount importance to ultrasonic melt processing. Hence, the last decade has witnessed the emergence of various numerical models for predicting acoustic pressures and velocity fields in liquid metals subject to ultrasonic excitation at large amplitudes. This paper summarizes recent research, arguably the state of the art, and suggests best practice guidelines in acoustic cavitation modelling as applied to aluminium melts. We also present the remaining challenges that are to be addressed to pave the way for a reliable and complete working numerical package that can assist in scaling up this promising technology.Engineering and Physical Sciences Research Council (EPSRC), U

Contactless ultrasonic cavitation in alloy melts

A high frequency tuned electromagnetic induction coil is used to induce ultrasonic pressure waves leading to cavitation in alloy melts. This presents an alternative ‘contactless’ approach to conventional immersed probe techniques. The method can potentially offer the same benefits of traditional ultrasonic treatment (UST) such as degassing, microstructure refinement and dispersion of particles, but avoids melt contamination due to probe erosion prevalent in immersed sonotrodes, and it can be used on higher temperature and reactive alloys. An added benefit is that the induction stirring produced by the coil, enables a larger melt treatment volume. Model simulations of the process are conducted using purpose-built software, coupling flow, heat transfer, sound and electromagnetic fields. Modelling results are compared against experiments carried out in a prototype installation. Results indicate strong melt stirring and evidence of cavitation accompanying acoustic resonance. Up to 63% of grain refinement was obtained in commercial purity (CP-Al) aluminium and a further 46% in CP-Al with added Al–5Ti–1B grain refiner

Comparison of frequency domain and time domain methods for the numerical simulation of contactless ultrasonic cavitation

The use of a top-mounted electromagnetic induction coil has been demonstrated as a contactless alternative to traditional ultrasonic treatment (UST) techniques that use an immersed mechanical sonotrode for the treatment of metals in the liquid state. This method offers similar benefits to existing UST approaches, including degassing, grain refinement, and dispersion of nanoparticles, while also preventing contact contamination due to erosion of the sonotrode. Contactless treatment potentially extends UST to high temperature or reactive melts. Generally, the method relies on acoustic resonance to reach pressure levels suitable for inertial cavitation and as a result the active cavitation volume tends to lie deep in the melt rather than in the small volume surrounding the immersed sonotrode probe. Consequently, (i) with suitable tuning of the coil supply frequency for resonance, the treatment volume can be made arbitrarily large, (ii) the problem of shielding and pressure wave attenuation suffered by the immersed sonotrode is avoided. However, relying on acoustic resonance presents problems: (i) the emergence of bubbles alters the speed of sound, resonance is momentarily lost, and cavitation becomes intermittent, (ii) as sound waves travel through and reflect on all the materials surrounding the melt, the sound characteristics of the crucible and supporting structures need to be carefully considered. The physics of cavitation coupled with this intermittent behaviour poses a challenge to sonotrode modelling orthodoxy, a problem we are trying to address in this publication. Two alternative approaches will be discussed, one of which is in the time domain and one in the frequency domain, which couple the solution of a bubble dynamics solver with that of an acoustics solver, to give an accurate prediction of the acoustic pressure generated by the induction coil. The time domain solver uses a novel algorithm to improve simulation time, by detecting an imminent bubble collapse and prescribing its subsequent behaviour, rather than directly solving a region that would normally require extremely small time steps. This way, it is shown to predict intermittent cavitation. The frequency domain solver for the first time couples the nonlinear Helmholtz model used for studying cavitation, with a background source term for the contribution of Lorentz forces. It predicts comparable RMS pressures to the time domain solver, but not the intermittent behaviour due to the underlying harmonic assumption. As further validation, the frequency domain method is also used to compare the generated acoustic pressure with that of traditional UST using a mechanical sonotrode

Controlling solute channel formation using magnetic fields

Solute channel formation introduces compositional and microstructural variations in a range of processes, from metallic alloy solidification, to salt fingers in ocean and water reservoir flows. Applying an external magnetic field interacts with thermoelectric currents at solid/liquid interfaces generating additional flow fields. This thermoelectric (TE) magnetohydrodynamic (TEMHD) effect can impact on solute channel formation, via a mechanism recently drawing increasing attention. To investigate this phenomenon, we combined in situ synchrotron X-ray imaging and Parallel-Cellular-Automata-Lattice-Boltzmann based numerical simulations to study the characteristics of flow and solute transport under TEMHD. Observations suggest the macroscopic TEMHD flow appearing ahead of the solidification front, coupled with the microscopic TEMHD flow arising within the mushy zone are the primary mechanisms controlling plume migration and channel bias. Two TE regimes were revealed, each with distinctive mechanisms that dominate the flow. Further, we show that grain orientation modifies solute flow through anisotropic permeability. These insights led to a proposed strategy for producing solute channel-free solidification using a time-modulated magnetic field