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Mathematical Modeling of Copper and Brass Upcasting PDF
Mathematical Modeling of Copper and Brass Upcasting PDF
A study has been performed to establish basic knowledge in heat transfer and solidification for copper
and brass upcasting. The study combined pilot scale measurements, mathematical modeling, and
metallographic examination of the cast rod samples. The pilot scale measurements involved temper-
ature measurements with several thermocouples inserted in the copper jacket of the mold. Temper-
ature measurements of the surface of the cast rod were carried out as well. A three-dimensional
(3-D) mathematical model of the copper mold and graphite die was constructed to characterize the
heat flux profiles quantitatively from the measured mold temperature data. The heat flux was observed
to have a maximum value near the first contact point between the copper mold and the graphite die
and to decrease rapidly with increasing distance up to the mold. The calculated heat flux profiles
were used as boundary conditions for another mathematical model, which calculated temperature
profiles in the cast rod. A model for estimation of material data and microstructure was used for
simulating the thermophysical data needed in the calculations and to predict certain microstructural
properties in the cast rods. The calculated surface temperatures of the cast rod at the mold exit agreed
well with the measured temperature values. Also, the calculated microstructural properties, such as
secondary dendrite arm spacing, phase distribution, and microsegregation of zinc, were in good
agreement with the measured ones.
I. INTRODUCTION from the rod to the mold has to increase in order to solidify
the rod in the mold.
CONTINUOUS casting of copper and brass bars and Numerous studies concerning continuous casting and its
rods generally used for the production of drawn wire can
mathematical modeling can be found from the literature.[3–23]
be accomplished by different commercial methods. In the Most of these publications, however, deal with the contin-
wheel and the belt methods,[1] the casting machine consists uous casting of steel rather than the continuous casting of
of a casting wheel with a machined groove of desired con-
copper and copper-based alloys. In the case of steel, the
figuration forming three sides of the casting cavity. A con-
heat flow along the casting direction is insignificant com-
tinuous steel band closes with the wheel, forming the fourth
pared to that along the cross-sectional direction, and can
side of the mold. In the Outokumpu Upcast system,[2] so-
therefore be neglected. This assumption is generally ac-
lidification occurs inside a submerged die after which the
cepted, due to the relatively low thermal conductivity of
solid rod is pulled vertically upward. The main advantages
steel. This means that the conductive heat flow along the
of the Upcast process over other methods of producing cop-
casting direction is negligible compared to the convective
per and brass wire rod are (1) the melt feeding can be con-
heat transport due to the casting speed. In copper and brass
trolled easily and accurately; (2) the Upcast production line
casting, this assumption is not valid, due to the higher ther-
is a multistrand unit, which gives flexibility in meeting the
mal conductivity, and one has to make the simulation three-
required capacity; (3) the coolers, including the graphite
dimensionally.
die, are individually changeable, so that a change of one
The aim of this study was to establish basic knowledge
cooler does not disturb other strands; and (4) it is possible
for copper and brass concerning heat transfer and solidifi-
to cast different strand shapes and sizes with the same cast-
cation in the mold of the upcasting device. This was
ing furnace.
achieved through temperature measurements, mathematical
Primarily, the casting of copper or brass can be consid-
modeling, and metallographic evaluation of rod samples. A
ered as a heat extraction process. The conversion of molten
better understanding of the casting process helps to opti-
metal into a solid metal rod involves removal of superheat
mize the casting conditions and, furthermore, to increase
and latent heat of solidification. The liquid metal is solid-
the plant productivity. The following experimental and
ified in a mold, which is the most critical and essential
modeling techniques were developed and used.
component of the continuous casting equipment. Heat
(1) Temperature measurements on an operating mold were
transfer in the mold is one of the main factors limiting the
carried out to determine the influence of casting speed
maximum productivity. With higher casting speeds, more
on the mold wall temperature distribution.
heat is transported into the mold and thus the heat transfer
(2) Temperature measurements of the outgoing cooling
water were carried out to determine the influence of
casting speed on the outgoing cooling water tempera-
ture.
K. HÄRKKI, Research Scientist, formerly with the Laboratory of (3) Metallographic analysis was used to examine the cast
Metallurgy, Helsinki University of Technology, is with Outokumpu rod samples.
PoriCopper, FIN-28101 Pori, Finland. J. MIETTINEN, Research Scientist,
is with the Laboratory of Metallurgy, Helsinki University of Technology,
(4) A three-dimensional (3-D) mathematical model (HTM)
FIN-02015 Espoo, Finland. was constructed with a commercial program package
Manuscript submitted March 31, 1998. (FIDAP) to simulate the heat transfer in the mold. The
~!
r
r2 ln 2
r1
mainly because of the restricted solute diffusion in the
solid, resulting in solute microsegregation and, conse-
quently, in a lower solidus temperature than shown by the
where kTOT is the total thermal conductivity of the air (in diagram. Therefore, nonequilibrium solidification paths had
W/m K), DT is the temperature gradient in the air gap (in to be calculated in this work, using the MDM model. This
Kelvin), r1 is the radius (in meters) of the cast wire rod, procedure is described in Appendix A.
and r2 is the inside radius (in meters) of the graphite die of
the mold. The term kTOT can be described as
IV. EXPERIMENTAL
kTOT 5 kLAM 1 kTUR [3]
The pilot scale trials were undertaken at the Outokumpu
where the term kLAM represents the thermal conductivity Copper Metal Laboratory (Pori, Finland) with a rod up-
when no turbulence is present, and kTUR describes the effect casting machine. The cast rod was 17 mm in diameter, and
of turbulence on the heat transfer. the cast materials were oxygen-free copper and four differ-
Heat exchange between the copper jacket of the mold ent brasses, 85/15 (copper 85 wt pct and zinc 15 wt pct,
and the cooling water takes place by convection. Heat flux respectively), 75/25, 70/30, and 65/35. Experiments were
by convection can be calculated with the equation carried out at five different casting speeds, 0.5, 0.7, 0.9,
q 5 a (T1 2 T2) [4] 1.1, and 1.3 m/min, for all the materials. Temperatures of
the molten metals in the furnace and the superheats are
where a is the heat transfer coefficient (in W/m2 K), T1 is shown in Table I. Mold temperature measurements were
the surface temperature of the copper mold (in Kelvin), and made during all the different castings. The water flow rate
T2 is the temperature of the cooling water (in Kelvin). Heat was changed from 15 to 25 L/min for copper castings, but
transfer from the mold to the cooling water is complex, and held constant at 25 L/min for the brass castings. Further-
the heat transfer coefficient depends on many different fac- more, samples of the cast rod were collected from all cast-
tors, such as the shape of the mold wall, the type charac- ings during the campaign for metallurgical investigation.
Material Casting Speed (m/min) Casting Temperature (7C) Superheat (7C) Solidus (7C) Liquidus (7C) Latent heat (J/g)
Copper 0.5 to 1.3 1150 66 1084 1084 208.7
Brass 85/15 0.5 to 1.3 1120 95 971 1025 191.4
Brass 75/25 0.5 to 1.3 1080 103 905 977 179.2
Brass 70/30 0.5 to 1.3 1020 70 900 950 167.9
Brass 65/35 0.5 to 1.3 980 59 897 921 153.2
~ ! ~ ! ~ !
] k
]T
]x
1
] k
]T
]y
1
] k
]T
]z
50 [5]
]x ]y ]z
where k is the thermal conductivity and T is the tempera-
ture.
The thermocouple wires were laid along the slots, and
the slots consisted of thermocouple wire without a flow of
cooling water. Because the thermocouple slots locally in-
crease the mold wall temperature, it was necessary to use
a 3-D model, although the basic construction of the mold
was axisymmetric. The thermocouple slots near the cooling
water side of the mold were not considered in the model,
since they were located very close to the cooling water.
Fig. 6—Flow diagram of the procedure adopted in this study.
The measured mold temperatures were converted into heat
fluxes at the cast copper or brass rod side of the graphite
secondary dendrite arm spacing. The samples were polished boundary. The procedure consisted of a manual iterative
and macroetched at Outokumpu Copper Metal Laboratory scheme, in which the heat flux profile at the hot face of the
to reveal the macrostructure of the samples. Chemical and mold was adjusted until the model predicted temperatures
microstructural analysis was carried out at Outokumpu Re- agreed with the measured values at the graphite die side of
search Oy. The microstructure examination was performed the mold.
with a scanning electron microscope (SEM) and the zinc The following assumptions were made when construct-
content of the samples was analyzed with the help of wave- ing the heat flow model.
length dispersive spectroscopy (WDS). (1) The mold was considered stationary. Variations in heat
flux due to forward-stop-forward motion of the cast
wire rod were ignored.
V. MATHEMATICAL MODELS (2) Heat flux across the top and bottom surfaces of the
mold and the surfaces within the slot was assumed to
For a better understanding of the heat transfer and solid- be zero.
ification procedures in the upcasting mold, mathematical (3) The temperatures at the cooling water side of the mold
models, HTM and HTR, were constructed to calculate the were used as boundary conditions, ignoring the distur-
temperature distribution and the heat fluxes in the mold and bance of those thermocouple slots on the heat flow.
cast copper and brass rods. Two separate models were con- (4) Intimate contact was assumed at the interface between
structed in order to avoid the problem of modeling the air the graphite die and the copper mold; i.e., the thermal
gap formation between the cast rod and the mold. Modeling resistance across the interface was assumed to be zero.
of the air gap formation would have required simultaneous In order to solve Eq.[5], the following boundary con-
treatment of heat transfer, solidification, and stress forma- ditions were used.
tion. This kind of simulation, however, is numerically very (5) Linear temperature interpolation functions on the cool-
difficult to carry out due to the highly nonlinear mechanical ing water side of the mold (TCS) were calculated from
behavior of metals just below the solidification temperature. the measured temperature points:
*H
C. Model for Material Data and Microstructure
cp 5 ]t
tot [10]
To obtain reliable results from the heat transfer and so-
The following assumptions were made when constructing lidification simulations, accurate thermophysical data for
the heat-flow model. the material, such as density, thermal conductivity, and en-
(1) The liquid flow of the melt was assumed to be equal thalpy, are needed. Typically, in metallic alloys, the ther-
to the casting speed; this means that liquid convection mophysical properties of individual solution phases are
in the radial direction was neglected. continuous functions of temperature. In the mushy zone,
(2) The flow field was assumed to be constant at any point however, there can be a drastic change in these properties,
in the cast copper or brass rod. depending on the intensity of the phase change. Additional
(3) Heat flux across the surface against the protective cup changes to the properties are caused by secondary solid
was assumed to be zero. phases, e.g., those formed as a result of the peritectic re-
(4) The heat flux boundary condition at the graphite side action in the mushy zone region.
was set as a boundary condition at the cast rod surface. The alloys in this study (Table I) primarily solidify to
(5) The cast rod section was assumed to have a fixed di- the solid fcc structure. In addition, some amount of bcc
mension, and consequently, constant density values phase is formed in brasses 70/30 and 65/35, which undergo
were used in the calculations. a peritectic reaction L 1 fcc → bcc at 903 7C. Note that
1 x LCu x Zn
L
[240,696 1 4403 (x LCu 2 x LZn) 1 7818 (x LCu 2 x LZn)2] T , 1500 K 27
H fcc
5x fcc
Cu (26727 1 11.528 1 1.8717T ln T 1 0.001111T ) 1 2
1x fcc
Zn (2230 2 64.741T 1 13.6083T ln T 2 0.005769T 2) 1
1x fcc
Cu Zn [242,804 1 2936 (x Cu 2 x Zn ) 1 9034 (x Cu 2 x Zn ) ]
x fcc fcc fcc fcc fcc 2
T , 1500 K 27
H bcc 5 x bcc
Cu (22710 1 11.528T 1 1.8717T ln T 1 0.001111T ) 1
2
1 x bcc
Zn (2313 2 64.741T 1 13.6083T ln T 2 0.005769T 2
)1
1 x bcc
Cu x bcc
Zn [251,596 1 7562 (x bcc
Cu 2 x bcc
Zn ) 1 30,744 (x Cu 2 x Zn ) ]
bcc bcc 2
T , 1500 K 27
r 5xL L
Cu (9086 2 0.801T) 1 x L
Zn (7336 2 1.1T) 1 x L
Cu x L
Zn (1143 1 0.268T) 28, 29
r fcc
5x fcc
Cu (9097 2 0.521T) 1 x fcc
Zn (7349 2 0.715T) 1
1 x fcc
Cu x Zn [(581 1 0.193T) 1 (2689 1 0.476T) z 10
25x ] fcc
fcc Zn
29 through 33
r bcc 5 x bcc
Cu (8268 2 0.109T) 1 x Zn (8765 2 1.186T)
bcc
30, 31
k 5xL L
Cu (127.2 1 0.0267T) 1 x L
Zn (9.3 1 0.058T)
1 x fcc
Cu x Zn [2378 2 2887 z 10
22.5x ] fcc
fcc Zn
29, 34
k bcc ' k fcc
Cu MCu 1 x Zn MZn, H in J/g is obtained (here, x i
*By dividing the enthalpy functions with x nom is the nominal composition and Mi is the atomic
nom nom
weight of component i). References on the right refer to the original data exploited in the evaluation process.
~ !
equations of phase interfaces (fcc/L, bcc/L, fcc/bcc) and ]G f
Fick’s second law of solute diffusion in a solid (fcc and Hf 5 Gf 2 [18]
bcc) on a scale of one volume element set on the side of a ]T P
r 5 1/ @r fL
L
1
f fcc
r fcc
1 bcc
r #
f bcc
[21]
liquid and the fcc phase of brass. where ff is the fraction of phase f (f 5 L, fcc, bcc, f L 1
f fcc 1 f bcc 5 1), and Hf, rf, and kf are the molar enthalpy,
where Gf is the molar Gibbs energy of liquid, fcc, and bcc the density, and the thermal conductivity of that phase, re-
phases given as spectively. Functions based on Eq. [17] for Hf, rf, and kf
have been given in Table II. In the case of thermal con-
Gf 5 f
x Cu f
(0G Cu 2 H Cu
SER
) 1 x Zn
f f
(0G Zn 2 H Zn
SER
) ductivity in Eq. [22], Amix is a liquid-convection parameter
1 x Cu RT ln x Cu 1 x Zn RT ln x Zn 1
f f f f
[19] where value zero means no convection in the liquid. In the
1 x fCux Zn
f
[0L fCuZn 1 1L fCuZn (x fCu 2 x fZn) upcasting process of this study, the convection was as-
1 2 f
L CuZn (x Cuf
2 x Zn
f 2
)] sumed to be negligible, and hence, Amix 5 0. These Eqs.
[20] through [22] of the phase change region are, of course,
In Eq. [19], 0GCuf-HCuSER and 0GZnf-HZnSER describe the also valid in single phase regions L, fcc, and bcc. For ex-
Gibbs energies of pure Cu and Zn in phase f relative to a ample, above the liquidus temperature, f L 5 1 and P 5 PL,
special reference state SER,[35] and nLCuZnf (n 5 0, 1, 2) are and below the solidus temperature, f L 5 0 and P 5 f fccPfcc
VI. RESULTS
In this work, temperature measurements, metallographic
analysis, and mathematical modeling have been applied to
establish a basic knowledge of heat transfer and solidifi-
Fig. 12—Temperature profiles at the graphite die side of the mold for cation in the upcasting mold for copper and brasses. The
brass 65/35. experimental part of the results is presented in the following
three sections: A, B, and C, showing temperature measure-
ments of the mold, temperature measurements of the cool-
ing water, and metallographic analysis of the cast rod
samples. The theoretical part of the results was produced
with the mathematical models in Section V and is presented
here in Section D. This section also presents some com-
parisons between measured and calculated results, giving
an estimation of the validity of the models.
Fig. 19—Transverse and longitudinal cross sections of the brass 85/15 rod
with different casting speeds.
Fig. 22—Transverse and longitudinal cross sections of the brass 65/35 rod
with different casting speeds.
Fig. 20—Transverse and longitudinal cross sections of the brass 75/25 rod
2. Microstructure
with different casting speeds. The microstructure of the samples was also analyzed.
Figure 23 shows the microstructure of brass 65/35. This
macro-and microsegregation. The samples were polished structure could only be revealed for brass 65/35. The den-
and macroetched to reveal the macrostructure of the sam- drites in Figure 23(a) are from the centerline of the longi-
ples. The microstructure of the samples was studied with tudinal cross section. After revealing the dendritic structure
an SEM, and the macro- and microsegregation of zinc in in a specimen, quantitative determinations of some micro-
the samples was analyzed with WDS. structural dimensions of dendrites are usually made. In
most studies, attention has been focused on measuring the
1. Macrostructure spacings of secondary dendrite arms grown from the pri-
Each sample was cut vertically and horizontally and was mary dendrite trunks. The secondary dendrite arms between
metallographically prepared. The macrostructure resulting the centerline and the surface of brass 65/35 can be clearly
from solidification could be clearly revealed by macroetch- seen in Figure 23(b).
ing the copper and the brass rods. Figures 18 through 22 Figures 24 and 25 show the phase distribution in the cast
D. Mathematical Models
Fig. 24—Microstructure of brass 65/35 showing some bcc phase (dark
areas) in the fcc matrix (light area). For a further understanding of the heat transfer and the
solidification phenomena in the upcasting mold, three math-
ematical models, HTM, HTR, and MDM (Section V) were
applied.
1. Mold model (HTM)
The comparison of the axial temperature profiles between
the graphite die side and cooling water side of the mold
show that there are differences in the temperatures along
the length of the copper mold (Figures 11 through 14). The
observed differences cannot be rationalized without a quan-
titative description of the heat transfer in the mold. Thus,
the HTM model of the mold was constructed to characterize
the heat transfer rates from the measured mold temperature
data.
Figures 26 through 30 show the heat flux profiles cal-
culated using the 3-D HTM model. As can be seen, the
interfacial heat flux during solidification has a maximum
peak value varying from 8000 to 14000 kW/m2 (close to
the first contact point between the copper mold and the
graphite die) and a minimum value varying from 800 to
Fig. 25—Microstructure of brass 70/30 showing a pure fcc structure with 2200 kW/m2 (at the mold exit level), depending on the cast-
no bcc phase. ing speed and the cast material. Increasing the casting speed
Fig. 27—Calculated heat flux profiles at the graphite interface for brass
85/15.
Fig. 30—Calculated heat flux profiles at the graphite interface for brass
65/35.
Fig. 33—Shape and position of the solidus front (S) and the liquidus front
(L) for brass 85/15 at different casting speeds.
Fig. 34—Shape and position of the solidus front (S) and the liquidus front
(L) for brass 65/35 at different casting speeds.
Fig. 37—Center and surface temperatures along the length of the mold
for brass 75/25 at casting speeds of 0.5 and 1.3 m/min.
Fig. 35—Center and surface temperatures along the length of the mold
for copper at casting speeds of 0.5 and 1.3 m/min.
Fig. 39—Center and surface temperatures along the length of the mold
for brass 65/35 at casting speeds of 0.5 and 1.3 m/min.
for pure copper only. Notice that in Figure 42, the thermal
conductivity of copper has been divided by three in order
to show it with the thermal conductivities of the brasses in
the same figure.
Figure 43 shows the solidification paths of the studied
brasses. In all of them, the primary solidifying phase is fcc.
Brasses 70/30 and 65/35, in addition, undergo a peritectic
transformation at a temperature close to 900 7C. This trans-
formation is soon completed, due to the rapid growth of
the bcc phase. After the liquid has disappeared, the inter-
dendritic composition soon decreases due to the high dif-
fusivity in the bcc phase, and because of the increasing
interface composition xZnbcc with the decreasing temperature
(Figure 3), the value of the gradient (dxZn/df )bcc/fcc finally
Fig. 45—Comparison of calculated and measured fractions of the bcc
changes its sign from positive to negative. This suppresses
phase in brass 65/35 at room temperature. the growth of the bcc phase toward the fcc phase and forces
the bcc/fcc interface to migrate backward, toward the bcc
J/g for brass 85/15, L 5 179.2 J/g for brass 75/25, L 5 phase (i.e., the sign of term Df bcc/fcc changes from negative
167.9 J/g for brass 70/30, and L 5 153.2 J/g for brass to positive). This happens in a narrow temperature range
65/35. below the solidus temperature, as shown in Figure 43.
Figure 41 shows the calculated density functions. The Figure 44 shows the dendrite arm spacings at different
higher the zinc content of the alloy, the lower the density cooling rates measured in brasses 67/33[38] and 65/35 (this
value of that alloy. On the basis of these density data, one work). These data were used to optimize the following re-
lation between the dendrite arm spacing d2 (in mm) and
can estimate the relative contraction of the mushy zone as z
b(pct) 5 100[1 2 r (TL)/r (TS)], where r (TL) is the density cooling rate T (in K/s):
at the liquidus temperature TL and r (TS) is the density at z
d2 5 56(T)20.33 [23]
the solidus temperature TS. The following values were ob-
tained for pure Cu and the studied alloys: b(pct) 5 4.71 Equation [23] was applied in the calculations of the MDM
for pure Cu,b(pct) 5 4.15 for brass 85/15, b(pct) 5 3.81 model. The cooling rate in Eq.[23] refers to the average
for brass 75/25, b(pct) 5 3.20 for brass 70/30, and b(pct) cooling rate in the mushy zone region.
5 2.37 for brass 65/35, showing that the higher the Zn For the validation of the MDM model, some calculated
content of the alloy, the smaller the relative contraction of results for bcc phase fractions and microsegregations of
the mushy zone. zinc were compared with the measured data. Figure 45
The calculated thermal conductivity functions are illus- shows the correlation between the calculated and the mea-
trated in Figure 42. As can be seen, the zinc alloying de- sured amount of the bcc phase in brass 65/35 at room tem-
creases the thermal conductivity, especially that of the solid perature. The agreement is quite good.
phase. On the other hand, the original data for solid brasses Finally, Figures 46 and 47 show a correlation between
were limited to the room temperature data, and their tem- the calculated and measured microsegregations of zinc in
perature dependency was adopted from the measurements the cast brasses. Here, the microsegregation is determined
was clear that the heat flux in the mushy zone was more in
E. Rod Model
the radial direction at higher casting speeds. Observing the
0.5 m/min casting examples revealed that, with increasing The results of the axisymmetric rod model, which was
zinc content, the orientation of the columnar grains tends used to simulate the heat transfer and solidification in the
to change to a more radial direction. This could be ex- cast rod, are presented in Section VI–D. The surface tem-
plained by the lower thermal conductivity of the cast ma- perature of the cast rod was measured for copper and
terials containing more zinc. The heat transfer along the brasses 85/15 and 75/25 by attaching two thermocouples to
casting direction decreased with increasing zinc content. the surface of the rods (Figure 5). The calculated surface
The average grain size becomes smaller with increasing temperatures at the mold exit are compared with the mea-
casting speed, as the grains have a shorter time to grow at sured temperature values in Figure 49. As can be seen from
high temperatures just below the solidus temperature. Fig- Figure 49, the agreement between the experimental and the
ure 48 shows the residence time at the temperature range calculated temperature values is quite good. However, the
of Tsolidus-1000 K as a function of the casting speed for cop- simulated surface temperature values are, in all cases, 5 7C
per. to 15 7C higher than the experimental values. This temper-
Small equiaxed grains tend to nucleate on the mold sur- ature difference may originate from the fact that, with high
face where nucleation sites are found. No center equiaxed cooling rates, the latent heat released during solidification
structure was found, as there was insufficient undercooling can be lower than expected on the basis of the tabulated
for a homogeneous nucleation, due to the high superheats thermodynamic data. This decrease in the latent heat can
used. be explained by the formation of lattice defects during so-
The results of the phase distribution showed that brass lidification.[10,36] When lattice defects are formed, the free
65/35 contained some bcc phase in the fcc matrix, whereas energy of the solid increases in proportion to the amount
the other brasses had a pure fcc structure with no bcc phase. and type of defects. Each defect formed during the solidi-
These observations were verified by the MDM model cal- fication increases the enthalpy of the solid, and thus, the
culations. latent heat will decrease. If the latent heat used in the HTR
~ !
distribution, and the microsegregation of zinc, were fcc/L
compared with the measured ones, showing good agree- 4D fccDT dxZn
ment. M fcc
Zn 5 z [A6]
d 2T df
following chemical-potential-equality equations: as ffcc 5 f fcc 1 Df fcc/L. If the temperature reaches the peri-
tectic temperature, Tp 5 1176 K, the simulation is removed
m fCu1 (T, x Zn
f1
) 5 m Cu
f2 f2
(T, x Zn ) [A1]
to region L 1 fcc 1 bcc (Chapter B). Otherwise, the so-
lidification is continued in region L 1 fcc, until, with fcc
m fZn1 (T, x Zn
f1
) 5 m Zn
f2 f2
(T, x Zn ) [A2] fraction f fcc 5 1, one has reached the nonequilibrium sol-
where mCuf and mZnf are the chemical potentials of Cu and idus temperature and the solidification is ended.
Zn in phase f (f 5 L, fcc, bcc) defined according to the When applying Eq. [A6], one has to know the values for
substitutional solution model as parameters Dfcc and d. Based on the measured fcc diffusiv-
ities in Cu-Zn alloys[29] the following function was opti-
m fCu 5 f
(0G Cu 2 H Cu
SER
) 1 RT ln (1 2 x Zn f
) mized for Dfcc (in cm2/s) (Figure. A2):
1 x Zn L CuZn 1
f 2 0 f
[A3] D fcc 5 0.078 z exp (11.62 z x Zn
fcc
) z exp
1 (3x fZn 2 2 4x fZn 3) 1L fCuZn
(2174,730/RT) [A7]
1 (5x fZn 2 2 16x fZn 3 1 12xfZn 4)2L fCuZn
i.e., with increasing Zn contents, the diffusivity increases
m fZn 5 f
(0G Zn 2 H Zn
SER
) 1 RT ln x Zn f (here, aMxfcc
Zn refers to the average composition of Zn in the
1 (1 2 2x fZn 1 x fZn 2)0L fCuZn 1 fcc phase calculated from the concentration profile). An es-
1 (1 2 6x fZn 1 9x Zn 2 4x fZn 3)1L fCuZn timation for the dendrite arm diameter d (in cm) as a func-
f 2
[A4] z
tion of cooling rate T (in K/s) was obtained from Eq. [23],
1 (12 10x Zn 1 29x Zn 2 32x Zn
f f 2 f 3
correlating well with the measured data for brass 63/37/38/
1 f 4 2 f
12x Zn ) L CuZn and brass 65/35 of this study, as shown in Figure. 49.
1 0.12922 z 10 T 1 52,478/T
26 3
T , 1358 K
5 213,542.3 1 183.8042T 2 31.38T ln T 1 3.64643 z 1029T 29 T . 1358 K
0
G Zn
fcc
2 H SER
Zn 5 24316.0 1 116.8996T 2 23.7013T ln T 2 1.71,203 z 10 T 2 1.26496 z 10 T
23 2 26 3
T , 693 K
5 28100.8 1 170.7752T 2 31.38T ln T 1 4.70657 z 1026T 29 T . 693 K
CuZn 5 242,804 1 10.023T
L fcc
0
0
G Cu
bcc
2 H SER
Cu 5 23753.5 1 129.2304T 2 24.11239T ln T 2 2.65684 z 10 T 1
23 2
(a) (b)
Fig. A1—Composition and phase fraction terms of interfacial material Fig. A2—Calculated vs experimental[29] fcc diffusivities in brasses.
balance equations concerning (a ) the fcc/L interface in region L 1 fcc
and (b ) the bcc/L and the bcc/fcc interfaces in region L 1 fcc 1 bcc. the following interfacial mass balance equations (Figure.
A1(b)):
B. Region L 1 Fcc 1 Bcc
Df bcc/L (x L,0
Zn 2 x Zn )
bcc
In region L 1 fcc 1 bcc, temperature is decreased step- 5 (1 2 f 2 f bcc 2 Df bcc/L) (x LZn 2 x L,0
fcc
Zn ) 1 M Zn
bcc
[A8]
wise, Eqs. [A1] and [A2] are applied to calculate compo-
sitions xbcc
Zn and xZn of interface bcc/L and compositions
L
Df bcc/fcc (x bcc'
Zn 2 x Zn ) 5 2M Zn 1 M Zn [A9]
fcc bcc fcc
xZn and xZn of interface bcc/fcc, and the fractional move-
bcc ' fcc
~ !
fcc/bcc
4D DT dxZn
fcc the solute begins to accumulate ahead of the advancing den-
M fcc
Zn 5 z [A11] drite tips, leading to the undercooling of the liquid phase.
d 2T df
At medium to high growth rates (dendritic regime), one can
In these equations, f fcc and f bcc are the fractions of the fcc approximate the undercooling DT (in 7C) as [26]
~ !
and bcc phases, xZnL,0 and xZnL are the liquid compositions
1
of the bcc/L interface at the previous and the present tem- DT ' mC0 1 2 [B1]
perature steps, xZnbcc and xZnbcc' are the bcc compositions of 1 2 (1 2 k)P
the bcc/L and the bcc/fcc interfaces, xZnfcc is the fcc com-
position of the bcc/fcc interface, MZnbcc is a parameter de- where the Peclet number P is defined as
=2mC VG
scribing the amount of Zn leaving the bcc/L interface and
entering the bcc/fcc interface in phase bcc, MZnfcc is a param- P'p [B2]
eter describing the amount of Zn leaving the fcc/bcc inter- (1 2 k)D
0
face in phase fcc, Dbcc (in cm2/s) is the chemical diffusion In these equations, C0 is the nominal composition of solute
coefficient in the bcc phase given as[29] (in wt pct), m is the liquidus slope (in 7C/wt pct), k is the
partition coefficient of solute defined as the ratio of solid
D bcc 5 0.0069 z exp (278,700/RT) [A12] and liquid composition, V is the growth rate of dendrite tips
and (dxZn/df)fcc/bcc is the concentration gradient in the fcc (in cm/s), G is the Gibbs–Thomson coefficient (in cm 7C),
phase at the bcc/fcc interface. The other terms, Dfcc, DT, d, and D is the diffusion coefficient of solute in liquid (in
z cm2/s). When applying Eqs. [B1] and [B2] in the present
and T, are explained in Section A. Again, after each tem-
perature step, the diffusion in the fcc phase is simulated study, the following parameter values were used: C0 5 15,
with the implicite finite difference application of Fick’s sec- 25, 30, and 35 wt pct (nominal Zn compositions of the
z studied alloys), m 5 24.85 7C/wt pct and k 5 0.85 (av-
ond law using the time increment Dt 5 DT/T. This yields
the the concentration gradient (dxZn/df) fcc/bcc
for the next erage liquidus slope and partition coefficient for the studied
temperature step. In addition, the present liquid composi- alloys taken from the phase diagram of Figure 3), V 5 0.45
tion value is set to the old value as xZnL,0 5 xZnL and the cm/s (average growth rate of dendrite tips estimated from
fractions of the fcc and the bcc phases are changed as f fcc the temperatures of Figures 35 through 39), G 5 1.5z1025
5 f fcc 1 Df fcc/fcc and f bcc 5 f bcc 1 Df bcc/L 2 Df bcc/fcc. These cm 7C[26] (value for pure copper melts, but assumed to be
calculations are repeated until, with solid fraction f fcc 1 f bcc valid for Cu-Zn melts also), and D 5 5.10z1025 cm2/s (typ-
5 1, one has reached the nonequilibrium solidus tempera- ical value of solute diffusion coefficient in the liquid phase,
ture and the calculations are removed to region fcc 1 bcc. a measured value for Zn in Cu-Zn melts not available). This
Note that in Figure A1(b), the bcc phase grows to both resulted in undercoolings from 4 7C to 6 7C for the studied
directions, i.e., term Df bcc/L is positive but term Df bcc/fcc is brasses (the higher the Zn content, the higher the under-
negative. This is due to the very high diffusivity in the bcc cooling). It is worth remembering that the applied param-
phase (compare Eq. [A12] to Eq. [A7]). In addition, the eter combination given above fulfills the validity condition
high diffusivity in the bcc phase allowed the straight-line P(1 2 k ) , 1 of Eqs. [B1] and [B2].
approximation for the concentration profile of bcc phase in
Fig. A1(b). According to test calculations of bcc diffusion ACKNOWLEDGMENTS
with Fick’s second law, only slightly different Mbcc terms
were obtained for the bcc/L and the bcc/fcc interfaces, The authors thank Professor Lauri Holappa, Helsinki
whereas in the present treatment, they were assumed to be University of Technology and Outokumpu Copper Products
equal. Metal Laboratory (Pori), and the Outokumpu Foundation
for financial support.
C. Region Fcc 1 Bcc
In region fcc 1 bcc, temperature is decreased stepwise, REFERENCES
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xZnbcc and xZnfcc of interface bcc/fcc, and the fractional move- ed., Pergamon Press, Oxford, United Kingdom, 1986, pp. 832-39.
ment of the interface, Df bcc/fcc, is simulated with Eq. [A9], 2. S. Pietilä: Non-Ferrous Wire Handbook, 3rd ed., Wire Association
International Inc., Guilford, CT, 1995, pp. 204-10.
where the term MZnbcc is now given as 3. R.B. Mahapatra, J.K. Brimacombe, I.V. Samarasekera, N. Walker,
~ !
bcc/fcc
E.A. Paterson, and J.D. Young: Metall. Trans. B, 1991, vol. 22B, pp.
4D bcc DT dxZn 861-73.
M bcc
Zn 5 z [A13] 4. R.B. Mahapatra, J.K. Brimacombe, and I.V. Samarasekera: Metall.
d 2T df Trans. B, 1991, vol. 22B, pp. 875-88.
5. I.V. Samarasekera, D.L. Anderson, and J.K. Brimacombe: Metall.
Here, term (dxZn/df )bcc/fcc is the concentration gradient in the Trans. B, 1982, vol. 13B, pp. 91-104.
6. I.V. Samarasekera and J.K. Brimacombe: Metall. Trans. B, 1982, vol.
bcc phase at the bcc/fcc interface obtained in each step by 13B, pp. 105-16.
applying the implicite finite difference application of Fick’s 7. B.G. Thomas: Steelmaking Conf., Iron and Steel Society, Washington,
second law for the diffusion in the bcc phase. DC, 1991, vol. 74, pp. 105-18.