The formation of freckles in binary alloys

Abstract

This paper presents a synopsis of some recent work, still in progress, aimed at elucidating a quantitative explanation of the processes by which flow chimneys form when certain types of alloys are directionally solidified. If (for example) light fluid is released at the liquid-solid "mushy " (dendrite) zone, and cooling is from below, then the intermediate fluid flow undergoes convection through the porous dendrite mass. This can lead to an "instability " of the form of the mushy zone, such that upwelling light fluid flows preferentially in channels within the dendrite mass. What we seek to develop here, is a mathematical basis by which this phenomenon may be properly understood. Accordingly, a mathematical model is developed, simplified, and partially analysed, and as a result we are able to make one specific prediction concerning a criterion for the onset of convection and freckling. This prediction is equivalent to the classical Rayleigh number condition for convective instability. 1