Mesoscopic Simulation of Dendritic Growth Observed in X-ray Video Microscopy During Directional Solidification of Al–Cu Alloys

Abstract

A mesoscopic model is developed to simulate microstructures observed in situ by X-ray video microscopy during directional solidification of Al–Cu alloys in a Hele–Shaw cell. In the model, a volume-averaged species conservation equation is solved to obtain the solute concentration and solid fraction fields, and an analytical stagnant film model is used to predict the motion of the dendrite envelopes. The model is carefully validated in several test cases. Then, the model is applied to simulate the columnar dendritic microstructures observed in the X-ray video microscopy experiments for two different alloy compositions. Reasonable agreement is found between the measured and predicted dendrite envelope shapes, solid fractions, and solute concentration fields. The predicted size of the mushy zone and the extent of the undercooled melt region ahead of the columnar front agree well with the in situ experimental observations. The simulation results show quantitative agreement with the internal solid fraction variations measured from the radiographs. The present model is also able to realistically simulate a primary dendrite trunk spacing adjustment that was observed in one of the experiments. Overall, the present study represents the first successful validation of a solidification model using real time, in situ data from an experiment with a metallic alloy. Considerable additional research is needed to account in the model for the effect of gravity driven melt convection.