Analytical, numerical, and experimental analysis of inverse macrosegregation during upward unidirectional solidification of Al-Cu alloys

Ivaldo L. Ferreira, Carlos A. Santos, Vaughan R. Voller, Amauri Garcia

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40 Scopus citations

Abstract

The present work focuses on the influence of alloy solute content, melt superheat, and metal/mold heat transfer on inverse segregation during upward solidification of Al-Cu alloys. The experimental segregation profiles of Al 4.5 wt pet Cu, 6.2 wt pct Cu, and 8.1 wt pct Cu alloys are compared with theoretical predictions furnished by analytical and numerical models, with transient h i profiles being determined in each experiment. The analytical model is based on an analytical heat-transfer model coupled with the classical local solute redistribution equation proposed by Flemings and Nereo. The numerical model is that proposed by Voller, with some changes introduced to take into account different thermophysical properties for the liquid and solid phases, time variable metal/mold interface heat-transfer coefficient, and a variable space grid to assure the accuracy of results without raising the number of nodes. It was observed that the numerical predictions generally conform with the experimental segregation measurements and that the predicted analytical segregation, despite its simplicity, also compares favorably with the experimental scatter except for high melt superheat.

Original languageEnglish (US)
Pages (from-to)285-297
Number of pages13
JournalMetallurgical and Materials Transactions B: Process Metallurgy and Materials Processing Science
Volume35
Issue number2
DOIs
StatePublished - Apr 2004

Bibliographical note

Funding Information:
The authors acknowledge financial support provided by FAPESP (The Scientific Research Foundation of the State of São Paulo, Brazil) and CNPq (The Brazilian Research Council).

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