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Investigations on metallurgical parameters in hypoeutectic Al–Si alloys under upward directional solidifications

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Abstract

The solidification thermal parameters such as solidification speed, cooling rate, and local solidification time were determined and correlated with tertiary dendritic arm spacings. Microsegregation profiles were experimentally determined from the central region of the dendritic arms to the interdendritic regions under different solidification speeds. A phase-field model was considered in the simulations of the solidification process in hypoeutectic Al–Si alloys. In order to improve the predictive capacity of the present model, the solidification speed effects were considered through the incorporation of the effective partition coefficients. Those partition coefficients, in turn, have been experimentally determined for a wide range of solidification speeds. The values of effective partition coefficient and cooling rate obtained from experiments were considered in the calculations. The tertiary dendrite arm spacings for both alloys were predicted by the phase-field model in regions close to the water-cooled system. The present-work-based numerical results show a good agreement with dendrite arm spacings determined from the experimental procedure. The microsegregation phenomenon, which is the inhomogeneous distribution of solute at the scale of dendrite spacings, was calculated by the phase-field model. The microsegregation profiles of silicon solute, determined by the model, yielded appreciable agreement from the experimental data. Finally, solidification speed was predicted by the model. While effective partition coefficient and cooling rates obtained from experiments were considered during calculations, a good agreement can be observed for solidification speed. Through numerical examples, the applicability of the phase-field model to the problems of dendrite arm spacings, microsegregation, and solidification speed in Al–Si alloys directionally solidified is demonstrated.

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Availability of data and material

The data that support the findings of this study are available from the corresponding author on reasonable request.

Code availability

For image processing, Tecplot software was used. Fortran 90 was used for simulations.

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Funding

This work was supported by the Fundação de Amparo à Pesquisa do Estado do Rio de Janeiro (FAPERJ, APQ#1: E-26/010.001942/2019) and Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq no. 305181/2019–0, PQ—2019).

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Authors and Affiliations

  1. Graduate Program On Metallurgical Engineering, Universidade Federal Fluminense, Volta Redonda, RJ, 27255-125, Brazil

    Alexandre Furtado Ferreira, Lucas Jardim de Moura, Bruno Silva Dantas & Roberto Carlos Sales

  2. Mechanical Engineering Department, Universidade Federal Fluminense, Volta Redonda, RJ, 27255-125, Brazil

    Fábio José Bento Brum

  3. Federal Institute of Rio de Janeiro, Volta Redonda, RJ, 27213-100, Brazil

    Wysllan Jefferson Lima Garção

Authors
  1. Alexandre Furtado Ferreira
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  2. Lucas Jardim de Moura
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  3. Bruno Silva Dantas
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  4. Fábio José Bento Brum
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  5. Wysllan Jefferson Lima Garção
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  6. Roberto Carlos Sales
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Contributions

Alexandre Furtado Ferreira: investigation, formal analysis, and writing—original draft. Lucas Jardim de Moura: conceptualization and resources. Bruno Silva Dantas: conceptualization and resources. Fábio José Bento Brum: writing—review and editing. Wysllan Jefferson Lima Garção: experiments of solidification. Roberto Carlos Sales: simulations and analysis of images.

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Correspondence to Alexandre Furtado Ferreira.

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Ferreira, A.F., de Moura, L.J., Dantas, B.S. et al. Investigations on metallurgical parameters in hypoeutectic Al–Si alloys under upward directional solidifications. Int J Adv Manuf Technol 121, 7359–7382 (2022). https://doi.org/10.1007/s00170-022-09836-3

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  • DOI: https://doi.org/10.1007/s00170-022-09836-3

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