A solutal interaction mechanism for the columnar-to-equiaxed transition in alloy solidification

Abstract

A multiphase/multiscale model is used to predict the columnar-to-equiaxed transition (CET) during solidification of binary alloys. The model consists of averaged energy and species conservation equations, coupled with nucleation and growth laws for dendritic structures. A new mechanism for the CET is proposed based on solutal interactions between the equiaxed grains and the advancing columnar front—as opposed to the commonly used mechanical blocking criterion. The resulting differences in the CET prediction are demonstrated for cases where a steady state can be assumed, and a revised isotherm velocity (VT) vs temperature gradient (G) map for the CET is presented. The model is validated by predicting the CET in previously performed unsteady, unidirectional solidification experiments involving Al-Si alloys of three different compositions. Good agreement is obtained between measured and predicted cooling curves. A parametric study is performed to investigate the dependence of the CET position on the nucleation undercooling and the density of nuclei in the equiaxed zone. Nucleation undercoolings are determined that provide the best agreement between measured and calculated CET positions. It is found that for all three alloy compositions, the nucleation undercoolings are very close to the maximum columnar dendrite tip undercoolings, indicating that the origin of the equiaxed grains may not be heterogeneous nucleation, but rather a breakdown or fragmentation of the columnar dendrites.