Hostname: page-component-cd9895bd7-q99xh Total loading time: 0 Render date: 2024-12-18T22:15:16.308Z Has data issue: false hasContentIssue false

Compositional convection in the solidification of binary alloys

Published online by Cambridge University Press:  26 April 2006

P. W. Emms
Affiliation:
Mathematical Institute, Oxford University, 24–29 St. Giles’, Oxford OX1 3LB, UK
A. C. Fowler
Affiliation:
Mathematical Institute, Oxford University, 24–29 St. Giles’, Oxford OX1 3LB, UK

Abstract

When a binary alloy is directionally solidified, a two-phase mushy dendritic zone is often formed. Interdendritic convection of the melt may occur, and is coupled with compositional convection of the residual melt. If fluid flow velocities are high enough, local melt-back of the dendrites may occur, leading to channel formation, and thus preferred flow paths. In order to predict the onset of convection, a coupled liquid/mush model is proposed, which includes most of the known physics. An elaborate scaling procedure leads to certain conclusions concerning the nature of convection, and points to a much simplified model, which can essentially be solved analytically. Predictions of the theory are compared quantitatively with experiments.

Type
Research Article
Copyright
© 1994 Cambridge University Press

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

Amberg, G. 1991 Computation of macrosegregation in an iron-carbon cast. Intl J. Heat Mass Transfer 34, 217227.Google Scholar
Amberg, G. & Homsy, G. M. 1993 Nonlinear analysis of buoyant convection in binary solidification with application to channel formation. J. Fluid Mech. 252, 7998.Google Scholar
Beckermann, C. & Viskanta, R. 1988 Double-diffusive convection during dendritic solidification of a binary mixture. PhysicoChem. Hydrodyn 10, 195213.Google Scholar
Bennon, W. D. & Incropera, F. P. 1987a A continuum model for momentum, heat and species transport in binary solid-liquid phase change systems – I. Model formulation. Intl J. Heat Mass Transfer 30, 21612170.Google Scholar
Bennon, W. D. & Incropera, F. P. 1987b The evolution of macrosegregation in statically cast binary ingots. Metall. Trans. 18B, 611616.Google Scholar
Chen, C. F. & Chen, F. 1991 Experimental study of directional solidification of aqueous ammonium chloride solution. J. Fluid Mech. 227, 567586.Google Scholar
Copley, S. M., Giamei, A. F., Johnson, S. M. & Hornbecker, M. F. 1970 The origin of freckles in unidirectionally solidified castings. Metall. Trans 1, 21932204.Google Scholar
Drew, D. A. & Wood, R. T. 1985 Overview and Taxonomy of Models and Methods for Workshop on Two-Phase Flow Fundamentals. National Bureau of Standards, Gaithersburg, Maryland.
Eltayeb, L. A. & Loper, D. E. 1991 On the stability of vertical double-diffusive interfaces. Part 1. A single plane interface. J. Fluid Mech. 228, 149181.Google Scholar
Emms, P. W. 1993 Compositional convection and freckle formation in a solidifying binary alloy. D.Phil. thesis, Oxford University.
Flemings, M. C. 1974 Solidification Processing. McGraw-Hill.
Flemings, M. C. & Nereo, G. E. 1967 Macrosegregation: Part I. Trans. Metall. Soc. AIME 329, 14491461.Google Scholar
Fowler, A. C. 1985 The formation of freckles in binary alloys. IMA J. Appl. Maths 35, 159174.Google Scholar
Fujii, T., Proctor, D. R. & Flemings, M. C. 1979 Macrosegregation in a multi-component low steel alloy. Metall. Trans. 10B, 331339.Google Scholar
Ganesan, S. & Poirier, D. R. 1990 Conservation of mass and momentum for the flow of interdendritic liquid during solidification. Metall. Trans. 21B, 173181.Google Scholar
Hills, R. N., Loper, D. E. & Roberts, P. H. 1983 A thermodynamically consistent model of a mushy zone. Q. J. Mech. Appl. Maths 36, 505539.Google Scholar
Howard, L. N. & Veronis, G. 1987 The salt-finger zone. J. Fluid Mech. 183, 123.Google Scholar
Huppert, H. E. 1990 The fluid mechanics of solidification. J. Fluid Mech. 212, 209240.Google Scholar
Huppert, H. E. & Worster, M. G. 1985 Dynamic solidification of a binary melt. Nature 314, 703707.Google Scholar
Jacobs, J. A. 1953 The earth's inner core. Nature 172, 297298.Google Scholar
Kou, S., Poirier, D. R. & Flemings, M. C. 1978 Macrosegregatin in rotated remelted ingots. Metall. Trans. 9B, 711719.Google Scholar
Loper, D. E. & Roberts, P. H. 1978 On the motion of an iron alloy core containing a slurry I. General theory. Geophys. Astrophys. Fluid Dyn. 9, 289321.Google Scholar
Loper, D. E. & Roberts, P. H. 1980 On the motion of an iron-alloy core containing a slurry II. A simple model. Geophys. Astrophys. Fluid Dyn., 16, 83127.Google Scholar
Loper, D. E. & Roberts, P. H. 1981 Compositional convection and the gravitationally powered dynamo. In Stellar and Planetary Magnetism (ed. A. M. Soward), pp. 297327. Gordon and Breach.
Maples, A. L. & Poirier, D. R. 1984 Convection in the two-phase zone of solidifying alloys. Metall. Trans. 15B, 163172.Google Scholar
McDonald, R. J. & Hunt, J. D. 1969 Fluid motion through the partially solid regions of a casting and its importance in understanding A-type segregation. Trans. Metall. Soc. AIME 245, 19931997.Google Scholar
McDonald, R. J. & Hunt, J. D. 1970 Convective fluid motion within the interdendritic liquid of a casting. Metall. Trans 1, 17871788.Google Scholar
Mehrabian, R., Keane, M. & Flemings, M. C. 1970a Experiments on macrosegregation and freckle formation. Metall. Trans. 1, 32383241.Google Scholar
Mehrabian, R., Keane, M. & Flemings, M. C. 1970b Interdendritic fluid flow and macrosegregation; Influence of grvity. Metall. Trans. 1, 12091220.Google Scholar
Neilson, D. G. & Incropera, F. P. 1991 Unidirectional solidification of a binary alloy and the effects of induced fluid motion. Intl J. Heat Mass Transfer 34, 17171732.Google Scholar
Ni, J. & Beckermann, C. 1991 A volume-averaged two-phase model for transport phenomena during solidification. Metall. Trans. 22B, 349361.Google Scholar
Proctor, M. R. E. 1981 Steady subcritical thermohaline convection. J. Fluid Mech. 105, 507521.Google Scholar
Ridder, S. D., Kou, S. & Mehrabian, R. 1981 Effect of fluid flow on macrosegregation in axisymmetric ingots. Metall. Trans. 12B, 435447.Google Scholar
Roberts, G. O. 1977 Fast viscous convection. Geophys. Astrophys. Fluid Dyn. 8, 197233.Google Scholar
Roberts, G. O. 1979 Fast viscous Bénard convection. Geophys. Astrophys. Fluid Dyn. 12, 235272.Google Scholar
Roberts, P. H. & Loper, D. E. 1983 Towards a theory of the structure and evolution of a dendrite layer. In Stellar and Planetary Magnetism (ed. A. M. Soward), pp. 329349. Gordon and Breach.
Sample, A. & Hellawell, A. 1982 The effect of mold precession on channel and macro-segregation in ammonium chloride-water analog castings. Metall. Trans. 13B, 495501.Google Scholar
Sample, A. K. & Hellawell, A. 1984 The mechanisms of formation and prevention of channel segregation during alloy solidification. Metall. Trans. 15A, 21632173.Google Scholar
Sarazin, J. R. & Hellawell, A. 1988 Channel formation in Pb–Sn, Pb–Sb, and Pb–Sn–Sb alloy ingots and comparison with the system NH4Cl-H2O. Metall. Trans. 19A, 18611871.Google Scholar
Schmitt, R. W. 1970 Flux measurements on salt fingers at an interface. J. Mar. Res. 37, 419437.Google Scholar
Stern, M. E. 1975 Ocean Circulation Physics. Academic.
Szekely, J. & Jassel, A. S. 1978 Experimental and analytical study of the solidification of a binary dendritic system. Metall. Trans. 9B, 389398.Google Scholar
Tait, S. & Jaupart, C. 1992 Compositional convection in a reactive crystalline mush and melt differentiation. J. Geophys. Res. 97 (B5), 67356756.Google Scholar
Taylor, G. I. 1953 Dispersion of soluble matter in solvent flowing slowly through a tube. Proc. R. Soc. Lond A 219, 186203.Google Scholar
Thompson, M. E. & Szekely, J. 1988 Mathematical and physical modelling of double-diffusive convection of aqueous solutions crystallizing at a vertical wall. J. Fluid Mech. 187, 409433.Google Scholar
Turner, J. S. 1973 Buoyancy Effects in Fluids. Cambridge University Press.
Veronis, G. 1987 The role of the buoyancy layer in determining the structure of salt fingers. J. Fluid Mech. 180, 327342.Google Scholar
Woodruff, D. P. 1973 The Solid–Liquid Interface. Cambridge University Press.
Worster, M. G. 1986 Solidification of an alloy from a cooled boundary. J. Fluid Mech. 167, 481501.Google Scholar
Worster, M. G. 1991 Natural convection in a mushy layer. J. Fluid Mech. 224, 335359.Google Scholar
Worster, M. G. 1992 Instabilities of the liquid and mushy regions during solidification of alloys. J. Fluid Mech. 237, 649669.Google Scholar