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Temperature, density, and velocity distribution in the mixture prepared by controlled diffusion solidification process

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Abstract

Controlled diffusion solidification (CDS) is a casting process that depends on mixing two precursor alloys to make a required resultant alloy. The CDS process can form a non-dendritic microstructure happening from copious nucleation, resulting in minimizing the tendency toward hot tearing. Pure aluminum was mixed into Al-33wt%Cu through funnels that have 9 and 6 mm diameters to make Al-4.7wt%Cu. Ansys software was employed to simulate the temperature, density, and velocity redistribution in the mixture during the mixing step. The results show that the thermal curves give better indications to predict the periods of nucleation and the heat transferring to the environment. Furthermore, the copious nucleation that occurs in the CDS process can be improved by controlling the agitation during the mixing step by decreasing the velocity of the mixture near the crucible wall and increasing the velocity in the middle of the mixture. The velocity around 1.7 ms−1 and 0.2 ms−1 happening at the middle and near crucible wall, respectively, gives better non-dendritic microstructure.

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taken from the lower thermocouple for the experiment named Ex6 to Ex8 involved in Table 1, a thermal curve for Ex6, b thermal curve for Ex7, and c thermal curve for Ex8

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Availability of data and materials

The experimental and simulation data are transparent.

Notes

  1. NIKON AZ 100 M is a trademark of Eberbach Corporation, Ann Arbor, MI.

  2. Ansys 15, Ansys Inc.

Abbreviations

Alloy1:

Precursor alloys

Alloy2:

Precursor alloys

Alloy3:

Resultant desired alloy

CCu :

Copper concentration wt%

Co :

Alloy3 concentration wt%

CP :

Specific heat of liquid (J kg−1 K−1)

K:

Liquid thermal conductivity (W m−1 C−1)

m1:

Mass of alloy1

m2:

Mass of alloy2

mr:

Mass ratio (m1/m2)

p:

Pressure (Mpa)

T:

Actual temperature (K)

T1 :

Alloy1 temperature (K)

T2 :

Alloy2 temperature (K)

TC :

Minimum temperature (K)

Tm :

Melting temperature of pure metal (K)

TLiq :

Liquidus temperature (K)

ΔT:

Undercooling below liquidus temperatures (K)

t:

Time (s)

tm :

Time of starting of mixing (s)

u:

Velocity (ms−1)

ρ:

Liquid density (kg m−3)

βT :

Coefficient of thermal expansion

βC :

Coefficient of solute expansion

µ:

Viscosity (mPa)

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Acknowledgements

The authors are grateful to Mr. Doug Culley, Mr. Xiaogang Li, and Xiaochun Zheng for assisting in this research project.

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  1. Department of Mechanical Engineering, McMaster University, 1280 Main Street W, Hamilton, ON, L8S 4L7, Canada

    Abbas A. Khalaf

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AAK designed the study, performed the research, analyzed the data, wrote the paper, and conducted experiments and data processing.

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Correspondence to Abbas A. Khalaf.

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Khalaf, A.A. Temperature, density, and velocity distribution in the mixture prepared by controlled diffusion solidification process. Int J Adv Manuf Technol 121, 3857–3870 (2022). https://doi.org/10.1007/s00170-022-09564-8

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