Lecture 7-8 (ME664)

ME664A
Fundamentals of Casting and Solidification
Dr. Arvind Kumar

Department of Mechanical Engineering
Indian Institute of Technology Kanpur
Lecture 7
Solidification Lab
Dr. Arvind Kumar Liquid Metals Group IIT Kanpur
3
5
Convection
Causes of melt flow during solidification

- Shrinkage
g
- Natural convection
- Forced convection
- Surface tension (Marangoni convection)
- Solid deformation
Shrinkage driven flow
Various simulation case studies
composition
Direct chill (DC)

No flow only shrinkage only natural natural convection
casting process + shrinkage
convection
Forced convection
Mould Liquid metal supply
Stirring
chamber
Electromagnetic
stirrer ((EMS))
Water spray
cooling
Solidified billet
Continuous Casting with linear

Electromagnetic stirring
Conventional continuous casting

Continuous casting with EMS but no transport of dendrites
Lorentz force field
Continuous casting with EMS as well as transport of dendrites Flow pattern by
streamlines
1
 ( J B) z  
2
Uref ~  g ( T T   S C )  Z
  ref  
Radial composition profile Dependence of flow
velocity on Lorentz force 9
Hhghf
10
Marangoni convection
The following equations describe the shear stress that the

Marangoni convection induces on the free surface
where µ and  are the fluid viscosity and surface tension,
respectively. These equations states that shear stress on the
f
free surface
f is
i proportional
ti l tto the
th temperature
t t gradient.
di t
These conditions are applied as a velocity boundary condition
at the top free surface of the melt pool formed.
Thus, whenever a temperature gradient exists in a liquid, so too does
a gradient in surface tension This gradient exerts a force
a gradient in surface tension. This gradient exerts a force
11
Solidification: natural conv
12
Hhghf
Hhghf
13
Solidification: natural conv in pure substance vs alloy

PURE SUBSTANCE ALLOY
H
L Fixed Comp.
H
Tm T L
C
O
L S L
D T
TS TL
Conduction only
C
C O
S L
O L +
L S D S
D L L
With convection 14
Specifics of alloy solidification
 Unlike pure substances, alloys do not have a sharp interface between

the solid and the liquid phases
• Solidification occurs over a range of temperature
• Mushy zone exists between phases
• Co-existence of thermal and solutal buoyancy
 Composition variations – segregations

• Solute is re-distributed as solidification occurs
• Solute transport has to be solved along with momentum and energy
15
16
ME664A
Fundamentals of Casting and Solidification
Dr. Arvind Kumar

Department of Mechanical Engineering
Indian Institute of Technology Kanpur
Lecture 8
Solidification Lab
Governing transport equations during solidification
18
Example problem
Ref: W.D. Bennon and F.P. Incropera, “A continuum model for momentum, heat and
species transport in binary solid-liquid phase change systems – II. Application
to solidification in a rectangular cavity”, Int. J. Heat Mass Transfer, vol. 30, No.
10 pp.
10, pp 2171-2187,
2171 2187 1987.
1987
Problem Description:
L
• Rectangular
g domain filled with NH4Cl-H2O
• Initial condition Th = 311 K
Tc = 223 K
Mixture is fully liquid and at Ti = 311 K
Initial solute concentration is Ci = 0.7
07
• Top and Bottom walls are insulated.
• L = 0.025 m, H = 0.1 m H
• Numerical Simulation is shown for two case studies:
Differentially Heated Side Walls

Left Wall: Tc = 223 K,, Right
g Wall: Th = Ti = 311 K
19
• Continuum model: It uses the classical mixture theory to develop a single

set of mass,
mass momentum,
momentum energy and species conservation equations
equations,
which concurrently apply to the solid, liquid and mushy regions. The
numerical procedures for this model are much simpler since the same
equations are employed over the entire computational domain, thereby
facilitating use of standard, single-phase CFD procedures.
gl l gss
g l  g s  1, f l  f s  1, f l  , fs  ,   gl l  g s  s
 
Continuum
definition u  f l u l  f s u s , k  g l k l  g s k s , D  f l Dl  f s D s
20
Mathematical formulation
Continuity Equation
 
(  )  .(( u ) = 0
t
Momentum Equations
  p (1  fl ) 2
(  u ) + .(( u u ) =   ( u )  C u
t x b  fl 3
  p (1  fl )2
( v)+ .( u v) =
 ( v) 
y
C
b  fl 3
v reff g T (T  Treff )  S (Cl  Creff ) 
t
gl l gss
g l  g s  1, f l  f s  1, f l  , fs  ,   gl l  g s  s
 
Continuum
definition u  f l u l  f s u s , k  g l k l  g s k s , D  f l Dl  f s D s
• C~109 (large no.), b = small no. • Fully Liquid: fl = 1 No flow resistance

• Fully Solid: fl = 0  large flow resistance  • Mushy Region: 0 < f l< 1  Smooth variation
Solution for ui , vi ~ 0 of porous-medium resistance 21
Mathematical formulation (Contd..)
Energy Equation
  1   
( T )+ ( uT )={( gS S  gl l )T}   ( fl H )  (.  u H )
t c p  t 
Species Equation
   
( Cl ) .( u Cl ) .(D  Cl )    f s Cl   Cs   f s 
t t t
D   fl Dl
22
Example problem: differentially heated side walls 90 sec
Isotherms Stream Species Velocity Isotherms Stream Species Velocity

Tmax = 311 K F
Function
ti C
Concentration
t ti V t
Vectors Function
F ti Concentration
C t ti V
Vectors
t
Tmin = 223 K ψmax = 0.016 Clmin = 0.700 5.8 mm/s ψmax = 0.0153 Clmin = 0.700 5.5 mm/s
BENNON & INCROPERA

S
SIMULATION
A O
Benchmark exp result
23
Comprehensive casting modelling system
24
Flow in porous mushy zone with different morphology
Liquid
Solid
Mushy region
Solidification in a casting with

columnar microstructure
Solidification in a casting with

equiaxed microstructure Solidification in a casting
with mixed columnar-
equiaxed microstructure 25
Mushy
y zone p
permeability
y

Darcy equation ( g l vl )   p
K
1.0E+02
1 0E+01
1.0E+01 d 22 g l3
K
180 1  g l 
2
1.0E+00
d permeability
1.0E-01
1.0E-02
K / d2 )
2
1.0E-03
1.0E-04
Normalized
(K
1.0E-05
s s+l l
1.0E-06
1.0E-07
porous mushy zone of
1.0E-08 varying permeability ‘K’
1.0E-09
0 01
0.1 02
0.2 03
0.3 04
0.4 05
0.5 06
0.6 07
0.7 08
0.8 09
0.9 1
gl
26
Modelling flow in the mushy zone
 K
d 2 g l3
Darcy equation ( g l vl )   p
180 1  g l 
2
K
 (1  fl )2
In x direction: Sx =  u  C u
K b  fl 3

In y direction: Sy =  v 
K
(1  fl )2
= C v +
b  fl 3
27
28
Mathematical formulation (Contd..)
Energy Equation
  1   
( T )+ ( uT )={( gS S  gl l )T}    ( fl H )  (.  u H )
t c p  t 
29
Species Equation
   
( Cl ) .( u Cl ) .(D  Cl )    f s Cl   Cs   f s 
t t t
D   fl Dl
30
Binary Alloy Solidification (Contd..)
 Lever Rule (Equilibrium Solidification) Time t = 0
Cmix  f l Cl  f s Cs Liquid CL = Co
Time t = t*
 Scheil’s Rule (Non
(Non--Equilibrium Solidification)
Solid (Cs*) Liquid (CL*)
(Cl  CS ) df S  (1 f S ) dCl CL*
COMPOSITION
Co
 C dV   C dV
Cmix   l l l  s s s CS* LEVER
V
gs
CL*
Cmix  l f l Cl  s  Cs dgs
0 Co
CS*
fl  mass fraction of liquid SCHEIL
f S  mass fraction of solid DISTANCE
CS  solid phase composition
Cl  liquid phase composition
31
Solid fraction temperature relation
of fs with T is assumed.
Derive such
expression for
lever rule
32
33
34
It can be seen from the figure that the fraction formation
per degree df/dT is largest at the beginning of the solidification
process. Note that the function (7.17) is only valid
down to the eutectic temperature.
35
36
Solid fraction temperature relation for pure metal
Tliquidus – Tsolidus = a small ∆T ~ 1-2 ºC
37
Temperature
p BC
38
Example problem
Ref: W.D. Bennon and F.P. Incropera, “A continuum model for momentum, heat and
species transport in binary solid-liquid phase change systems – II. Application
to solidification in a rectangular cavity”, Int. J. Heat Mass Transfer, vol. 30, No.
10 pp.
10, pp 2171-2187,
2171 2187 1987.
1987
Problem Description:
L
• Rectangular
g domain filled with NH4Cl-H2O
• Initial condition Th = 311 K
Tc = 223 K
Mixture is fully liquid and at Ti = 311 K
Initial solute concentration is Ci = 0.7
07
• Top and Bottom walls are insulated.
• L = 0.025 m, H = 0.1 m H
• Numerical Simulation is shown for two case studies:
Differentially Heated Side Walls

Left Wall: Tc = 223 K,, Right
g Wall: Th = Ti = 311 K
39
Example problem: differentially heated side walls 90 sec
Isotherms Stream Species Velocity Isotherms Stream Species Velocity

Tmax = 311 K F
Function
ti C
Concentration
t ti V t
Vectors Function
F ti Concentration
C t ti Vectors
V t
Tmin = 223 K ψmax = 0.016 Clmin = 0.700 5.8 mm/s ψmax = 0.0153 Clmin = 0.700 5.5 mm/s
BENNON & INCROPERA

S
SIMULATION
A O
Benchmark exp result
40
Final Macrosegregation Along Horizontal Direction
PRESCOTT et al (1994) FLUENT SIMULATION
h*=0
h 0.083
083
h*=0.50
41
Comprehensive casting modelling system
42
43
eby the thermmo-
and hence itts usability

mechanical properties of the cast
Macrosegregation- compositions variations

asting qualitty and there
COUPLING
omponents a
Ca
co
d i filling
during filli
m
After effect of
casting process
completion… so
depends on the
phenomena taking
place during casting 44
• It can be clearly seen that the filling and feeding systems are separate, which is
appropriate since they perform completely different functions in the production of a casting.
• It might take ~ 10 seconds to fill the mould, whereas the feeding system would typically be
operating for ~10 minutes as the casting solidifies.
45
Example problem of mold filling
46
47
48
49
50
51
Recap
 Convection during solidification
 Mathematical formulation for pure metal and alloy
solidification
 Mushy zone, momentum, energy and species transport
 Simulation example
 Application of modelling simulation to predict and
explain
l i solidification,
lidifi ti d
defects
f t andd as-solidified
lidifi d properties
ti
 Mold filling modelling and simulation
52

Lecture 7-8 (ME664)

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ME664A

Fundamentals of Casting and Solidification

Dr. Arvind Kumar

Causes of melt flow during solidification

Direct chill (DC)

Continuous Casting with linear

Conventional continuous casting

The following equations describe the shear stress that the

Solidification: natural conv

Solidification: natural conv in pure substance vs alloy

 Unlike pure substances, alloys do not have a sharp interface between

 Composition variations – segregations

Dr. Arvind Kumar

Governing transport equations during solidification

• Numerical Simulation is shown for two case studies:

Differentially Heated Side Walls

• Continuum model: It uses the classical mixture theory to develop a single

• C~109 (large no.), b = small no. • Fully Liquid: fl = 1 No flow resistance

Mathematical formulation (Contd..)

Isotherms Stream Species Velocity Isotherms Stream Species Velocity

BENNON & INCROPERA

Comprehensive casting modelling system

Solidification in a casting with

Solidification in a casting with

Solid fraction temperature relation

Tliquidus – Tsolidus = a small ∆T ~ 1-2 ºC

• Numerical Simulation is shown for two case studies:

Differentially Heated Side Walls

Example problem: differentially heated side walls 90 sec

Isotherms Stream Species Velocity Isotherms Stream Species Velocity

BENNON & INCROPERA

Comprehensive casting modelling system

eby the thermmo-

and hence itts usability

Macrosegregation- compositions variations

Example problem of mold filling

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

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