Three-Dimensional Numerical Simulation and Experimental Investigations of Benchmark Experiment of Sn-10 wt. %Pb Alloy Solidification Under Thermosolutal Convection

Abstract

A full three-dimensional (3D) numerical simulation of solidification was carried out for a benchmark experiment on a binary Sn-10 wt. %Pb alloy. The experiment process involves a melting stage, a first holding stage at constant temperature with electromagnetic stirring, setting a mean horizontal temperature difference (second holding stage), and finally solidification stage by decreasing the temperature under a imposed horizontal temperature gradient. The numerical model is applied only to investigate the solidification stage and compared with the measured temperature fields and macrosegregation obtained from the postmortem analysis. A columnar numerical model based on a two-phase volume-averaged approach is used for the numerical simulation, accounting for thermosolutal convection and assuming perfect microscopic mixing (lever rule) in the mushy zone. It demonstrates that such a model is able to predict stratification in the solute from the liquid phase and mushy zone during the solidification. The effect of the sedimentation on macrosegregations and channel segregation or freckles which develop during the solidification stage is also predicted by the model and compared with experimental data. Emphasis is given to the main factors that have a direct effect on the development and morphology of segregated channels, namely, the remelting phenomenon, dendrite fragmentation, and the solidification front instabilities.