Mushy Zone Research Articles

Experimental and computational studies on hot cracking in single laser tracks of aluminium alloy AA2024 and related implications for laser powder bed fusion

Laser powder bed fusion of high-strength aluminium alloys remains challenging due to the formation of hot cracks during the printing process. Hot cracking is a complex phenomenon involving a complex thermo-mechanical and metallurgical interplay. Such relationship needs to be fully understood to reap the benefits of advanced laser modulation (temporal and spatial) capabilities, now becoming available in PBF-LB. To this end, we explore the formation of hot cracks in single tracks produced using a simple spatial–temporal laser modulation characterised by laser pulses of various distance. The formation of cracks is then rationalised by physical and numerical modelling using multi-physics CFD simulation. We demonstrate that the area of the mushy zone at the back of the moving melt pool, dynamically contracts and expands according to the laser temporal regimes and find maxima in correspondence to the largest laser pulse distance and the time steps between exposures. By then analysing in detail in the crack observed in the printed parts fabricated with the same laser modulation, it is possible to conclude that the mechanisms leading to hot cracks in these specimens is analogous. In turn, the insights on single tracks can be extended, for the most part, to the case of bulk specimens. Nevertheless, printed specimens appear to be more sensitive to the erratic movement of the melt pool, due to the presence of a larger number of highly energetical grain boundaries and unintended microstructural defects (voids and inclusions), from which cracks can nucleate.Graphical

The Melt–Crystal Interface in the Production of Monocrystalline Sapphire via Heat Exchanger Method—Numerical Simulation Aspects

In this work, selected numerical simulation aspects are analyzed in terms of their effect on predictions of the m-c interface. The fixed-grid enthalpy porosity phase change model, which is highly attractive in the field of modeling sapphire crystallization processes, is examined for its sensitivity to the mushy zone parameter as well as the grid resolution. A further focus is set to the simulation of thermal transport including internal radiation in the crystal and the melt via the finite volume method. Depending on the purpose of the investigation, different requirements on the angular resolutions are relevant. While most of the m-c interface as well as the temperature distribution remain practically unchanged at reasonable resolutions, a high sensitivity of the m-c interface in the near-wall region is demonstrated. This sensitivity is also observed in terms of radiative transport and, hence, the total heat transfer.

Comparison of Different Numerical Models for Solidification of Paraffin-Based PCMs and Evaluation of the Effect of Variable Mushy Zone Constant

Comparison of Different Numerical Models for Solidification of Paraffin-Based PCMs and Evaluation of the Effect of Variable Mushy Zone Constant

Numerical study on the effects of strands consistency on metallurgical transport behaviours of low-carbon steel in tundish–submerged entry nozzle–mould systems

In this study, the innovative tundish–submerged entry nozzle (SEN)–mould systems that enabled data transmission between the tundish and the mould were constructed to investigate the effect of strands consistency on the metallurgical transport behaviours of low-carbon steel. The velocity magnitude near stopper-rod A and T-outlet A was notably low. Owing to inactive flow regions and temperature variations near the stopper-rods, the maximum temperature difference between T-outlet A and T-outlet B was approximately 2.8 K. In case 2, a vortex occurred near the right narrow face of the steel–slag interface, while no vortex was present near the left narrow face. In cases 3, 5 and 6, some streamlines existed approximately perpendicular to the steel–slag interface. These phenomena increased the possibility of slag entrainment via the upward flow mechanism and shear layer instability. Cases belonging to strand A featured a higher temperature gradient than cases belonging to strand B, and this trend was related to the temperature difference between T-outlet A and T-outlet B. The extreme differences in temperature gradient were 0.067 K/mm for case 3 and 0.056 K/mm for case 4. At an SEN port angle of 15°, strands consistency had the greatest influence on the uniformity of the temperature gradient. Different solutes exhibited similar distribution patterns, and solute segregation was closely related to the partition coefficient. Various velocity components and SEN structures determined the position of the impact point, thereby influencing fluid flow and temperature distribution in the mould. The concentration distribution of solutes was closely related to the velocity at T-outlet A/B. The thickness of the solidified shell and mushy zone closely depended on the temperature at T-outlet A/B. Strands consistency impacted metallurgical transport behaviours in the mould and the quality of the bloom.

A multi-scale modeling framework for solidification cracking during welding

A multi-scale multi-physics modeling framework has been developed to predict solidification cracking susceptibility (SCS) during welding. The framework integrates a thermo-mechanical finite element model to simulate temperature and strain rate profiles during welding, a cellular automata model to simulate the solidified microstructure in the weld pool, and a granular model to calculate the pressure drop in the mushy zone. Verification was achieved by comparing the model’s predictions with welding experiments on two steels, demonstrating its capability to accurately capture the effects of process parameters, grain refinement, and alloy composition on SCS. Results indicate that increasing welding velocity, while maintaining a constant power-to-velocity ratio, extends the size of the mushy zone and increases the maximum pressure drop in the mushy zone, leading to higher SCS. Grain refinement decreases separation velocities and the permeability of liquid channels, which increases SCS, but it also raises the coalescence temperature, resulting in an overall reduction in SCS. Alloy composition impacts SCS through thermal diffusivity and segregation. Lower thermal diffusivity or stronger segregation tends to elongate the mushy zone, resulting in an increase in SCS. This framework provides a robust tool for understanding the mechanisms of solidification cracking, optimizing welding parameters to prevent its occurrence, and comparing SCS of different compositions during alloy design.

Effects of the Mushy Zone on the Temperature Field and the Flow Field During GaInSb Crystal Growth with the Traveling Heater Method

Effects of the Mushy Zone on the Temperature Field and the Flow Field During GaInSb Crystal Growth with the Traveling Heater Method

Numerical investigation of spreading phenomena of molten corium using EISPH method

Understanding the behavior of molten corium is crucial for effective heat management and ensuring the integrity of reactor containment during severe nuclear incidents. Corium spreading is a complex multi-physics phenomenon influenced by hydrodynamics, heat transfer, and phase change. The Smoothed Particle Hydrodynamics (SPH) method is utilized to study corium flow, leveraging its ability to handle complex fluid dynamics and its compatibility with parallel computing architectures. This research examines two specific corium spreading cases: the VULCANO VE-U7 experiment, which is characterized by a wide mushy zone, and the FARO L26S experiment, noted for its narrow mushy zone. The study compares spreading lengths and temperature profiles over time with experimental data, offering a detailed analysis of the observed spreading behaviors. Variations in physicochemical properties result in distinct spreading patterns between the cases, highlighting the complexity of corium behavior under different scenarios. The findings demonstrate the applicability and capability of the SPH method in capturing various characteristics of corium spreading effectively.

Characteristics of Solidification Cracking for Ni-P Coated Cu-Al5052 Single-Mode Fiber Laser Welds

This study fundamentally examines the characteristics of solidification cracking in Cu-Al5052 single-mode fiber laser welding by utilizing uncoated and Ni-P coated Cu plates for the high durability busbar welding of pouch-type lithium-ion battery packs. Weld solidification cracking was confirmed regardless of Ni-P coating for both weld materials. However, there were differences in the regions of crack occurrence. Unlike the uncoated Cu-Al5052 welds where cracks occurred randomly within the fusion zone, for the Ni-P coated Cu-Al5052 welds, solidification cracks were concentrated near the faying surface of the upper and lower materials, particularly near the fusion line. The effect of the Ni and P components on the solidification cracking susceptibility, i.e., the welding solidification temperature range, was considered. Diffusion-controlled Scheil’s solidification calculations revealed that the mushy zone range enlarged with the use of a Ni coating layer. It was confirmed that an extremely wide mushy zone range of 1060 K was calculated at the solidification cracking region. Furthermore, P was also identified as an element that expands the solidification temperature range based on the Cu-P binary system. Consequently, during the laser welding of Cu-Al5052 dissimilar materials, the behavior of solidification cracking in the welds is influenced by the composition of the coating material and the incorporated composition within the weld fusion zone. Hence, it is necessary to select the optimal coating material and layer thickness considering weld solidification cracking susceptibility.

Simulation and experimental investigation of grain structure, residual stress,γ′ phases in single crystal blade

Ni-based superalloy turbine blades have been required components in contemporary aero-engine. Knowing the solidification behavior, residual stress at grain defects, and microstructure of directionally solidified turbine blades is a required condition to improve the service performance of directionally solidified turbine blades. Firstly, the temperature field evolution of the blade under the withdrawal rate of 3 mm/min was studied. The deviations in temperature distribution in the high-rate solidification (HRS) procedure, particularly near the platform, can lead to transformations in the mushy zone, potentially resulting in solidification defects. Secondly, the grain growth of hollow turbine blades was calculated using the cellular automaton-finite factor method. The simulated grain framework was essentially consistent with experimental results. A method of process bar addition based on physical field distribution is also proposed. This method involves designing a combination of one Y-shaped and two I-shaped rods to decrease the cooling rate of blade edges and eliminate stray grains (SG). Then, the residual stress distribution at the locations of stray grains and low-angle grain boundaries (LAGBs) was analyzed before and after the addition of process bars. Finally, discussions were held regarding the distribution of γ′ phases in grain defects and blades.

A microstructural thermo‐elastoplastic analysis of the mushy zone during laser beam welding

AbstractAs a modern method of contact free fusion, laser beam welding has gained importance in recent years. This is due to both the possibiliy of a high advance speed of the laser and low thermal distortion of the components compared to other welding processes, see Dal and Fabbro. These beneficial process properties follow from a focused laser, which thus results in a precise energy input. In addition, laser beam welding processes can be automated which makes the process attractive for a wide range of applications, cf. Dilthey. Nevertheless, various influences, like the temperature gradient, the chemical composition or process parameters, may have an effect on the occurrence of so‐called solidification cracks. Solidification cracks arise during solidification and occur in the area of the mushy zone, which is located behind the melt pool. The material behavior in the mushy zone is governed by a dendritic morphology. Due to this, liquid phase inclusions may occur in some parts of the mushy zone, see Hills et al.. When these trapped areas solidify, no further liquid phase can follow and a negative pressure is created. The resulting stresses can then lead to solidification cracks. In further studies, the geometry of the dendritic morphology will be generated on the basis of previous phase field simulations. These describe the dendrite growth controlled by the chemical concentration. The resulting geometry will then be simulated using the possibilities of a thermo‐elastoplastic material model, which will enable temperature‐driven imitation of growth. This contribution addresses the evolving state of the dendritic microstructure in a simplified manner. Therefore, for the first study, a simplified morphology is used, that is, no secondary arms and an elliptical geometry of the dendrites is assumed. Thermal as well as elastoplastic effects are already taken into account, in order to represent the inherent stress and strain states in the microstructure. These may be related to critical states leading to failure in the future.

Impact of key parameters on the numerical modelling of Phase-Changing phenomena in horizontal latent heat thermal energy storage

Numerous studies have focused on numerical investigations of the performance of the shell-and-tube Latent Heat Thermal Energy Storage (LHTES). However, many studies have often overlooked rigorous assessment of key parameters’ impact on the numerical simulation accuracy relative to experimental results. Therefore, this paper aims to develop a numerical model to track the solid–liquid interface during phase-changing phenomena in a horizontal LHTES system and investigate the effects of key parameters on the simulation accuracy. For this purpose, an experimental facility was built, and the numerical model was developed in ANSYS using the enthalpy-porosity method. During the simulation of the computational model, consideration was given to thermophysical properties (constant versus variable) of phase change material, contact resistance (zero versus nonzero), and the mushy zone constant (105, 5 × 105, and 106). The simulation results were compared with experimental data obtained from the in-house studies. The results showed that, compared to using constant thermophysical properties, employing variable thermophysical properties more accurately tracked the solid–liquid interface during melting. It substantially improved the simulation accuracy with a Root Mean Square (RMS) error less than 5 % for most of the temperature-measuring locations. Conversely, variable properties did not make a significant difference in the solidification process. The contact resistance due to the air gap was determined to be 0.035 m2·K/W for the current study. Furthermore, incorporating this resistance resulted in a more accurate approximation of the solid–liquid interface during melting, with RMS errors below 5 % across all locations. The study comparing different mushy zone constants recommended utilizing a slightly higher value of 106 for melting, whereas its impact on solidification was found to be insignificant.

Multiscale mushy layer model for Arctic marginal ice zone dynamics

Perhaps the most dynamic component of the Arctic sea ice cover is the marginal ice zone (MIZ), the transitional region between dense pack ice to the north and open ocean to the south. It widens by a factor of four while seasonally migrating more than 1600 km poleward in the Bering–Chukchi Sea sector, impacting climate dynamics, ecological processes, and human accessibility to the Arctic. Here we showcase a transformative mathematical modeling approach to understanding changes in MIZ location and width, focusing on their seasonal cycles as observed by satellites. We view the MIZ as a liquid-solid phase transition region, or mushy zone, on the scale of the Arctic Ocean. Invoking the physics of phase changes, the MIZ is modeled as a dynamic, multiscale composite material layer; this model captures 96% of the annual cycle of MIZ location and 78% of the annual cycle of MIZ width. Temperature in the upper ocean is described by a nonlinear heat equation with effective parameters obtained using homogenization theory for a random medium of ice floes in a sea water host. Observations and simulations together indicate that MIZ location closely tracks the below-ice 273 K isotherm while the width of the MIZ follows vertical heat flux convergence, but with a three-week lag.

A novel meshless radial basis reproducing kernel particle approach for 3D thermo-mechanical analysis of mushy zone phase-change problems

This paper presents a three-dimensional thermo-elastoplastic computational model for the analysis of phase change problems involving the mushy zone. The model utilizes a novel meshless radial basis reproducing kernel particle approach, incorporating a high-order kernel that integrates Gaussian and cosine functions. An energy balance equation for the entire domain is formulated using the effective heat capacity method, based on the enthalpy formulation. The governing equations are discretized using the Galerkin weak form to compute thermal residual stresses, with essential boundary conditions enforced through the penalty method. Plastic deformation is characterized using the von Mises criterion with isotropic hardening, and the strain term resulting from temperature-dependent material properties is incorporated into the incremental solution process. Determination of the plastic strain increment is based on the Prandtl–Reuss flow rule. The accuracy and efficiency of the proposed meshless approach were rigorously evaluated through numerical examples encompassing two- and three-dimensional problems. The computational results were compared against available analytical and validated numerical solutions. This comprehensive assessment substantiated the robustness and precision of the developed technique. The case studies presented elucidate the capacity of the novel meshless model to effectively predict temperature distributions and residual stress fields within mushy zone phase change phenomena, accommodating both regular and irregular geometries under various boundary conditions. Notably, the model demonstrated consistent stability and high accuracy across the spectrum of simulated scenarios, thus underscoring its potential as a valuable tool for investigating complex phase change processes.

Three-dimensional simulation on phase change heat transfer of moving spherical particle

Investigating the motion process of paraffin particle under a mesoscopic scale is very helpful to master the heat transfer mechanism of the mushy zone in solid–liquid phase change. Prior researches predominantly focused on either particle motion or phase change, without accounting for their coupling. In this study, the three-dimensional finite element method is used to solve the motion and heat transfer of the particle, taking into account the coupling of motion and phase change. The moving grid is employed to trace the interface of moving particles and liquid using the Arbitrary Lagrangian-Euler method, which is able to calculate flow and heat transfer in fluid region and allow grid deformation in solid region. The results indicate that uneven fluid velocity around the particles results in non-uniform temperature gradients on particle’s surface. In areas with larger temperature gradient, it melts more quickly and its deformation is obvious. The maximum is located at particle orientation angle 30°. Changing the size and direction of fluid velocity will reinforce or inhibit the movement of particle. The changing time of motion direction when fluid velocity is −0.03 m/s shorten 2.7 times than when fluid velocity is −0.01 m/s. The initial temperature of the surrounding fluid has a positive relationship with the particle melting rate. The channel width affects significantly the motion and melting of particle. The initial position of particle has an important effect on it’s falling movement, and the closer is close to the wall of channel, the greater the displacement of left and right movement.

Repairing weld for directly solidified Ni-based superalloy substrates using directed energy deposition of Inconel 625

Although the maintenance, repair, and operation of gas turbine systems are important issues in enhancing the operation of power units, advanced welding repair processes have limitations in depositing directionally solidified Ni-based superalloy components. To overcome this problem, in this study, a directed energy deposition method was applied to repair directionally solidified components using an Inconel 625 alloy. The rapid cooling rate and small laser beam diameter during directed energy deposition minimized the heat-affected zone and duration in the mushy zone, resulting in crack inhibition at the interface. The first laser scan partially melted the substrate and formed a mixing zone with a chemical composition gradient. By combining the chemical compositional gradient and dislocation accumulation due to repetitive solidification, that is, with the melting cycles of directed energy deposition, the thermal stability decreased, resulting in recrystallization and grain growth in the mixing zone. Consequently, the crack-free continuous interface of the partially repaired components did not induce tensile fracture near the interface. Although the mechanical properties of the IN625 deposit layer were degraded by severe heat treatment of the substrate, the results demonstrated that energy deposition with post-heat treatment is an effective approach in repairing Ni-based superalloy components without cracks and inclusion initiation.

Numerical simulation study on solidification proceoss of titanium slab ingot by electron beam cold hearth melting

Abstract Titanium and titanium alloys are key basic support materials in the field of engineering technology and high technology, and are widely used in the fields of natural gas transportation, chemical corrosion, and marine development. Titanium alloy ingots are often prepared with more solidification defects such as surface cracks and cold shuts, resulting in lower utilization of titanium metal and higher cost of titanium products. The root of this is the lack of in-depth knowledge of the ingot melting and casting process, and the failure to control the thermal conditions of the billet in the molding process within a reasonable range. In this study, based on the Lagrange Euler algorithm, combined with ProCAST finite element software to establish a numerical model, revealing the solid-liquid interface morphology, the length of the transition region, and the change rule of thermal stress under the influence of different process parameters in the solidification process of titanium slab ingot. The results show that with the increase in pulling speed, the depth of the solid-liquid phase line and the width of the mushy zone of slab ingot increase, and the length of the transition region grows. With the increase in casting temperature, the depth of the solid-liquid phase line of the slab ingot decreases, and the mushy zone gradually becomes narrower. The casting temperature and pulling speed are positively correlated with the value of the thermal stress equivalent stress in slab ingots, and the probability of cracks in the corners and ingot surface is higher. This study provides effective theoretical guidance for the realization of stable mass production of high-quality titanium slab ingot.

Reproducing wrought grain structure in additive IN718 through nanosecond laser induced cavitation

Pulsed laser assisted additive manufacturing has been demonstrated as a promising technology for controlling grain structure in 3D-printing processes. The integration of a nanosecond laser onto a wire arc additive manufacturing tool has enabled the localized printing of Inconel 718 with grain sizes meeting ASTM 9 standards (average measured grain size of 13.7μm) for wrought material within a single bead under solidification conditions that would otherwise produce 340μm columnar grains. The observed grain refinement holds promise, provided scale up is possible, for overcoming the highly anisotropic mechanical properties and microcracking associated with large columnar grains of Inconel 718 that have long stood in the way of leveraging the advantages of direct energy deposition printing techniques of difficult to machine alloys. Experiments on large bead sizes allowed for decoupling surface versus bulk nanosecond laser/liquid metal interaction mechanisms to determine that the source of the observed grain refinement is the collapse of cavitation bubbles originating from acoustic waves generated by momentum transfer into the melt of an ablation plasma. Additionally, experiments that increased the cavitation bubble density within the mushy zone during solidification by tuning the nanosecond laser scan path went beyond the 25 times reduction in grain size to a 70 times factor of refinement with a minimum average grain diameter approaching 4μm.

Numerical Study on the Effects of Variable Mushy Zone Constants on Fluid Flow and Heat Transfer in Bloom Mold

In previous studies, the mushy zone constant was assigned a fixed value or a value associated with dendrite characteristics at room temperature. However, elucidating the constitutive behaviors of mushy dendrites at high temperatures using solid dendrite characteristics at room temperature poses challenges. In this study, a numerical model was constructed to investigate the effects of variable mushy zone constants on fluid flow and heat transfer in the mold. The results revealed that “Zone Z‐1/2” exhibited a thinner solidified shell compared with the other zones, indicating a close correlation between heat transfer and thickness differences. Under default simulation conditions, the liquid steel cooled rapidly, leading to the dissipation of superheat. The mushy zone exhibited a wide range, with almost no pure liquid phase present in the mold. In cases 2, 3, and 4 within “Zone Z‐1/2”, the average thickness of the solidified shell gradually increased during solidification, indicating the absence of evident remelting phenomena in the mold. As the variable mushy zone constants increased, the local temperature gradient increased, while the local cooling rate decreased. The accuracy of the numerical model was validated through actual measurements and empirical formulas. The simulation results for case 4 exhibited a high degree of fitting.

Simulation of melting characteristics of thermal washing of the wax layer in the pipeline based on lattice Boltzmann method

ABSTRACT The escalation of transportation costs and the obstruction of pipelines due to wax deposition significantly impact the secure and efficient production of oil fields. The thermal washing method, characterized by its simplicity and cost-effectiveness, is widely employed for dewaxing crude oil gathering pipelines. The investigation of the melting mechanism of the wax layer during thermal washing is extremely important. In this paper, the two-zone composite model of multiphase flow-porous medium in the mushy zone is introduced into the solid-liquid phase change lattice Boltzmann model based on the enthalpy method, and the problem of circumferential inhomogeneity in the melting of the wax layer and the important influence of flow and heat transfer in the mushy zone on the thermal washing are systematically investigated. The demarcation point (γ tr) between the high and low liquid fraction zones is measured to be 0.81 by microscopic experiment. The impacts of varying γ tr and Ste numbers on wax melting at different circumferential locations are analyzed in detail. The results show that the melting efficiency of wax exhibits a nonlinear enhancement from − 90° to 90°. The melting efficiency of wax decreases with increasing γ tr for wax layers between 90° and − 45°. The melting efficiency of wax increases with higher Ste numbers at all angles. The Ste number increases from 0.42 to 5.0, and the melting efficiency of the wax layer at angles ranging from 90° to − 90° increases by factors of 2.16, 2.16, 2.20, 2.61, and 3.33 respectively. The growth of the Ste number improves the warming rate and shortens the generation time of convection at the center point of the wax layer. The research findings serve as a fundamental reference for formulating a rational and efficient thermal washing scheme.

An energy concisions analytical modelling approach with experimental verification for cutting performance assessment in EDM of Ti-based superalloy

Electric discharge machining (EDM) is a stochastic process which is commonly engaged for cutting of Ti-based difficult-to-cut alloys. Experimental investigation in EDM is costly and requires significant amount of time due to the complex nature of the process. Moreover, the energy intensive nature is another criticism associated to this technique. Therefore, this research is focused on developing an energy conscious mathematical model of the process while considering the categorical parameters like type of dielectric, electrode and nano-powder along with pulse time ratio. Taguchi design of experiment (DOE) has been executed for the experimentation. The comprehensive analysis of the findings depicts transformer oil (TO) delivers a remarkable improvement in MRR and SEC in comparison to other dielectric choices. Furthermore, brass electrode stands out for achieving the best surface finish. When it comes to micro-additives, SiC exhibits substantial potential in increasing MRR, and graphite gives a better surface finish. The process has also been effectively modeled which helps to predict material removal rate (MRR), surface roughness (SR) and specific energy consumption with decent precision which is the key contribution of this study. 3D simulation for EDM illustrates that the features of the crater are defined by the liquefied region, whilst the dynamics of the mushy zone play a crucial role in controlling and characterizing the microstructure size progression. The confirmatory experimental results revealed that the use of optimized parametric combinations demonstrate 90.87% improvement in MRR, 52.07% reduction in SR and 96.19% decrease in SEC in contest to the responses’ values obtained at non-optimal settings.