Analysis of a numerical benchmark for columnar solidification of binary alloys

Abstract

During the solidification of metal alloys, chemical heterogeneities at the scale of the product develop. It is referred to as "macrosegregation". Numerical simulation tools exist in the industry. However, their predictive capabilities are not validated and are still limited. A 2D numerical benchmark is presented, based on the solidification of metallic Pb-Sn alloys. Concerning the numerical benchmark, a "minimal" common model of solidification is assumed, including columnar growth without undercooling, fixed solid, isotropic permeability of the mushy region, local thermodynamic equilibrium, lever-rule assumption for the local average composition. We focus our attention on the numerical method used to solve the average conservation equations: Finite Volume, Finite Element, Velocity-Pressure coupling treatment, scheme for convective terms, etc. At this stage of the work, we cannot exhibit a reference solution. However we draw some conclusions on the effects of the grid dependency, in particular on the location and sizes of the segregate channels. The development of both thermally and solutal driven convections in the first stage of the process (cf. low Prandtl and high Lewis numbers) and the relative independency of the convective scheme are also discussed. This presentation also have the goal to call other contributors to join this benchmark [1] in order to enrich the exercise and to reach a reference solution for this important problem in metallurgy.