Using four-phase Eulerian volume averaging approach to model macrosegregation and shrinkage cavity

Abstract

This work is to extend a previous 3-phase mixed columnar-equiaxed solidification model to treat the formation of shrinkage cavity by including an additional phase. In the previous model the mixed columnar and equiaxed solidification with consideration of multiphase transport phenomena (mass, momentum, species and enthalpy) is proposed to calculate the as- cast structure including columnar-to-equiaxed transition (CET) and formation of macrosegregation. In order to incorporate the formation of shrinkage cavity, an additional phase, i.e. gas phase or covering liquid slag phase, must be considered in addition to the previously introduced 3 phases (parent melt, solidifying columnar dendrite trunks and equiaxed grains). No mass and species transfer between the new and other 3 phases is necessary, but the treatment of the momentum and energy exchanges between them is crucially important for the formation of free surface and shrinkage cavity, which in turn influences the flow field and formation of segregation. A steel ingot is preliminarily calculated to exam the functionalities of the model.