Progress and Application of Microstructure Simulation of Alloy Solidification

doi:10.11900/0412.1961.2017.00428

Acta Metall Sin

2018, Vol. 54

Issue (2): 193-203 DOI: 10.11900/0412.1961.2017.00428

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Progress and Application of Microstructure Simulation of Alloy Solidification

Tongmin WANG^1,², Jingjing WEI^1,², Xudong WANG^1,²(

), Man YAO^1,²

1 School of Materials Science and Engineering, Dalian University of Technology, Dalian 116024, China
2 Key Laboratory of Solidification Control and Digital Preparation Technology (Liaoning Province), Dalian University of Technology, Dalian 116024, China

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Tongmin WANG, Jingjing WEI, Xudong WANG, Man YAO. Progress and Application of Microstructure Simulation of Alloy Solidification. Acta Metall Sin, 2018, 54(2): 193-203.

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Abstract

Solidification structures are the interaction links between the alloy components and their mechanical properties. Scientifically comprehending about the formation mechanisms, dominant factors and control methods in alloy solidification has a significant effect on the structure control and optimization. Dendritic structure is the most frequently observed solidification microstructure of alloys and controlled by heat, solute, melt flow, capillary and many other factors. Modelling and simulating can accurately quantify various phenomena and evolution rules in the process of solidification, thus play an increasingly important role in the design, preparation, processing and performance optimization of alloy materials. Over the past two decades, remarkable progress has been made and various models have been proposed in microstructure simulation during alloy solidification process, such as deterministic method, phase field (PF), Monte Carlo (MC) and cellular automaton (CA). With the advantages of clear physical meaning, easily programming and high calculation efficiency, CA method has been widely applied in the study of solidification structure simulation and exhibits great advantages. Considering the current development level of computer hardware, numerical model and calculation method, microstructure simulation of large components mainly adopts macro-microscopic coupling calculation method, such as CA-FD/FE model. The heat transfer and other multi-physical fields are calculated at the level of coarse mesh, where as nucleation and dendritic growth are simulated at a much finer grid level. This paper reviews the main models and development of CA method used for nucleation simulation. The key aspects in the simulation of dendritic growth including mean solid-interface interface curvature, growth kinetics and the algorithm for eliminating “pseudo anisotropy” are discussed. Based on this, the development and application status of macro-micro coupling model during casting, directional solidification and other manufacturing fields are summarized. Finally, the existing problems and future tendency for simulation of solidification structures are analyzed.

Key words: alloy solidification nucleation dendritic growth cellular automaton structure simulation

Received: 16 October 2017

Fund: Supported by National Natural Science Foundation of China (No.51474047)

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https://www.ams.org.cn/EN/10.11900/0412.1961.2017.00428 OR https://www.ams.org.cn/EN/Y2018/V54/I2/193

Fig.1 Length scales in simulation of solidification structure (CA—cellular automaton, CET—columnar to equiaxed transition, SDAS—secondary dendritic arm spacing)

Fig.2 Relationship among grain density, nucleation distribution and cooling curve (t—time;

T L

—liquidus temperature;

ΔT

Δ T 1

and

Δ T 2

—undercooling;

Δ T N

and

Δ T σ

—mean nucleation undercooling and standard deviation of undercooling of Gaussian distribution;

N 1

and

N 2

—grain density; N_max—maximum density of nuclei)

Fig.3 Dendrite morphologies using different neighborhood configurations
(a) Von Neumann (b) Moore

Fig.4 Modified decentered square algorithm

Fig.5 Simulated dendritic morphologies with different preferred growth orientation (C—solute concentration)

Fig.6 Simulated solidification microstructure of 1/4 billet using CAFE model

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