Numerical Study of the Thermosolutal Convection Induced Macrosegregation during Columnar Solidification

Abstract

As a response to “call for contribution to a numerical problem for 2D columnar solidification of binary alloys” [Bellet et al., Int. J. Therm. Sci., Vol. 48(11)(2009), p. 2013], the macrosegregation in a Pb-18wt.%Sn benchmark casting is numerically studied with a two-phase columnar solidification model developed by the current authors. The studies were done with 2D calculations in response to the call, and a 3D calculation was performed to confirm the consistency with the 2D case. A grid-sensitivity study was done to ensure the reliability and accuracy of the present results. The segregation mechanism due to thermosolutal convection was analyzed and the uncertainties resulting from the inaccurate thermophysical properties, modelling and process parameters are discussed. The numerical model was evaluated by comparison with experiments.