Numerical Investigation of Segregation Evolution during the Vacuum Arc Remelting Process of Ni-Based Superalloy Ingots

Segregation defects greatly affect the service performance and working life of castings during the vacuum arc remelting (VAR) process. However, the corresponding research on the prediction of segregation defects is still not comprehensive. Through considering the influence of water-cooled crucible on the electromagnetic field inside an ingot, a full-scale model for the comprehensive prediction of freckles and macrosegregation defects during the VAR process is developed in this paper. The macroscopic solute transport phenomenon and the segregation behavior of Ni-5.8 wt% Al-15.2 wt% Ta alloy are predicted. The results indicate that the freckles are mainly concentrated in the lower region of the ingot. With the growth of the ingot, the solute enrichment channels gradually develop into solute enrichment regions, and the channel segregation evolves into macrosegregation. The Lorentz force mainly affects the flow pattern at the top of the molten pool, while the complex flow of multiple vortices is dominated by thermosolutal buoyancy. The maximum and minimum relative segregation ratio inside the ingot can reach 290% and −90%, respectively, and the positive segregation region accounts for about 79% of the total volume. This paper provides a new perspective for understanding the segregation behavior inside the ingot by studying the segregation evolution during the VAR process.

Experimental Study of the Effect of Intermittent Electromagnetic Stirring On the Columnar-Equiaxed Transition In Sn–10wt.%Pb Alloy Solidification

Experimental analysis of stratification, electromagnetic stirring and solidification were carried out for two solidification experiments for a binary Sn-10wt.%Pb alloy. The objective of this study is to examine the effect of forced convection driven by an Intermittent Traveling Magnetic Field (I-TMF) on the solidification process. Several aspects were investigated, namely thermal field, macrostructure, and ?nally segregation behaviour, as well as, morphology. The effect of the both thermal and solutal stratification on the intensity of the flow is discussed yet, showed that stratification has a stabilizing effect for the flow, which can also slow the convective hydrodynamic movements generated by the buoyancy forces. The consequence of this stratification on macrosegregations and channel segregation, which develop during the solidification period, is experimentally analysed. Electromagnetic stirring by intermittent traveling magnetic promotes the development of the columnar-equiaxed transition mechanism (CET), more particularly the refinement of the grain size. The results illustrate, also, that electromagnetic stirring effectively diminish macrosegregations significantly, while remaining inactive for reducing channels segregation development.

Characteristics, Mechanism and Criterion of Channel Segregation in NbTi Alloy via Numerical Simulations and Experimental Characterizations

Channel segregation (CS) is the most typical defect during solidification of NbTi alloy. Based on numerical simulation and experimental characterizations, we deeply elucidated its characteristics, formation mechanism, effecting factor and prediction criterion. According to acid etching, industrial X-ray transmission imaging, 3D X-ray microtomography and chemical analysis, it was found that in a casing ingot, by He cooling, finer grain size, weaker segregation and slighter CS can be obtained compared with air-cooled ingot. The simulation results of macrosegregation show that CS is caused by the strong natural convection in the mushy zone triggered by the thermo-solutal gradient. Its formation can be divided into two stages including channel initiation and growth. In addition, due to the stronger cooling effect of the He treatment, the interdendritic flow velocity becomes smaller, consequently lowering the positive segregation and CS and improving the global homogenization of the final ingot. Finally, to predict the formation of CS, the Rayleigh number model was proposed and its critical value was found to be 15 in NbTi alloy for the first time. When it is lower than the threshold, CS disappears. It provides an effective tool to evaluate and optimize the solidification parameters to fabricate the homogenized NbTi ingot in engineering practice.

Macrosegregation behavior of solute Cu in the solidifying Al-Cu alloys in super-gravity field

In this research, super gravity field was introduced to investigate the macrosegregation behavior of solute Cu in Al-Cu alloys in super gravity field systematically. And the macrosegregation mechanism was also explored by well-designed experiments. When Al-Cu alloys were solidified in super gravity field, the macrosegregation of solute Cu was generated and the solute Cu increases along the direction of super gravity field. The macrosegregation becomes severer with the increasing gravity coefficient and the solute content. When the Al-4.5wt%Cu alloy was solidified in super gravity field of G = 800, the copper content at the bottom position increases up to 8.48 wt% and that at the up position decreases to only 2.58 wt%, resulting in the positive segregation at the bottom and the negative segregation at the top of the sample. The segregation mechanisms are that solute-rich regions, which have a larger density than the main liquid, sediment toward the bottom of the sample under the effect of super gravity, and at the final solidification stage, super gravity can drive the residual solute-rich liquid to flow toward the bottom of the sample along the dendrite space (channel), which formed the super gravity channel segregation.