Abstract
A theoretical model is presented in this study for investigating the heat transfer problem during solidification of pure metals on a coated sinusoidal mold. The previous works are extended by considering effects of both the sinusoidal coating layer’s properties and prescribed temperature boundary condition at the lower surface of the mold on the solidification process. The thermal diffusivities of the shell, coating and mold materials are assumed to be infinitely large, and it helps us to solve two-dimensional heat conduction problem analytically. The effects of the ratios between the thermal conductivities of coating, shell and mold materials, coating thickness and the amplitude ratios between the wavelengths of coating and mold surfaces on the solidification process are investigated in detail. Furthermore, the inverse design problem for the directional solidification process is briefly discussed. The results show that the thickness of the coating causes the decrease in the amplitude of the undulation at the solidification front for all cases considered. When the ratio between the amplitudes of both surface wavelengths of the mold is negative, the decrease in the ratio between thermal conductivities of the shell and coating materials causes more uniform growth in the shell regardless of the amplitudes of wavelength ratio between the surfaces of the coating layer. A bandwidth for thermal conductivity ratio between the shell and coating materials is determined depending on the process parameters for more uniform growth.
Similar content being viewed by others
References
Evans, G.W.: A note on the existence of a solution to a problem of Stefan. Q. Appl. Math. 9, 185–193 (1951)
Douglas, J.: A uniqueness theorem for the solution of a Stefan problem. Proc. Am. Math. Soc. 8, 402–408 (1957)
Crank, J.: Free and Moving Boundary Problem. Oxford University Press, Oxford (1984)
Hill, J.M.: One-Dimensional Stefan Problems: An Introduction, Longman Scientific and Technical. Wiley, New York (1987)
Caldwell, J.; Kwan, Y.Y.: Nodal integral and enthalpy solution of one-dimensional Stefan problem. J. Math. Sci. 13(2), 99–109 (2002)
Caldwell, J.; Savovic, S.; Kwan, Y.Y.: Nodal integral and finite difference solution of one-dimensional Stefan problem. J. Heat Transfer 125, 523–527 (2003)
Vynnycky, M.; Mitchell, S.L.: On the numerical solution of a Stefan problem with finite extinction time. J. Comput. Appl. Math. 276, 98–109 (2015)
Mitchell, S. L.; M.Vynnycky, M.: On the numerical solution of two-phase Stefan problems with heat-flux boundary conditions. J. Comput. Appl. Math. 264, 49–64 (2014)
Kutluay, B.; Bahadir, A.R.; Ozdes, A.: The numerical solution of one-phase classical Stefan problem. J. Comput. Appl. Math. 81, 135–144 (1997)
Yang, H.; He, Y.: Solving heat transfer problems with phase change via smoothed effective heat capacity and element-free Galerkin methods. Int. Commun. Heat Mass. 37, 385–392 (2010)
Zabaras, N.; Mukherjee, S.: An analysis of solidification problem by the boundary element method. Int. J. Numer. Methods Eng. 24, 1879–1900 (1987)
Vu, T.V.; Truong, A.V.; Hoang, N.T.B.; Tran, D.K.: Numerical investigations of solidification around a circular cylinder under forced convection. J. Mech. Sci. Technol. 30(11), 5019–5028 (2016)
Pedroso, R.I.; Domoto, G.A.: Exact solution by perturbation method for planar solidification of a saturated liquid with convection at the wall. Int. J. Heat Mass Transfer 16, 1816–1819 (1973)
Huang, C.L.; Shih, Y.P.: Shorter communications: perturbation solution for planar solidification of a saturated liquid with convection at the wall. Int. J. Heat Mass Transfer 18, 1481–1483 (1975)
Pedroso, R.I.; Domoto, G.A.: Perturbation solutions for spherical solidification of saturated liquids. Int. J. Heat Mass Transfer 95, 42–46 (1973)
Stephan, K.; Holzknecht, B.: Perturbation solutions for solidification problems. Int. J. Heat Mass Transfer 19, 597–602 (1976)
Font, F.: A one-phase Stefan problem with size-dependent thermal conductivity. Appl. Math. Model. 63, 172–178 (2018)
Dragomirescu, F.I.; Eisenschmidt, K.; Rohde, C.; Weigand, B.: Perturbation solutions for the finite radially symmetric Stefan problem. Int. J. Therm. Sci. 104, 386–395 (2016)
Yigit, F.: Approximate analytical solution of a two-dimensional heat conduction problem with phase-change on a sinusoidal mold. Appl. Therm. Eng. 28, 1196–1205 (2008)
Yigit, F.: Perturbation solution for solidification of pure metals on a sinusoidal mold surface. Int. J. Heat Mass Transfer 50, 2624–2633 (2007)
Yigit, F.: One-dimensional solidification of pure materials with a time periodically oscillating temperature boundary condition. Appl. Math. Comput. 217, 6541–6555 (2011)
Demir, M.H.; Yigit, F.: Early time perturbation solution of solidification on a coated sinusoidal mould of finite thickness. Adv. Mater. Process. Technol. 1(3–4), 327–337 (2015)
Vu, T.V.; Tryggvason, G.; Homma, S.; Wells, J.C.: Numerical investigations of drop solidification on a cold plate in the presence of volume change. Int. J. Multiph. Flow 76, 73–85 (2015)
Vu, T.V.; Nguyen, C.T.; Khanh, D.T.: Direct numerical study of a molten metal drop solidifying on a cold plate with different wettability. Metals 8, 47–56 (2018)
Caldwell, J.; Kwan, Y.: Numerical methods for one-dimensional Stefan problems. Commun. Numer. Methods Eng. 20, 535–545 (2004)
Hu, H.; Argyropoulos, S.A.: Mathematical modelling of solidification and melting: a review. Modell. Simul. Mater. Sci. Eng. 4, 371–396 (1996)
Demir, M.H.; Yigit, F.: Effect of coating material on the growth instability in solidification of pure metals on a coated planar mold of finite thickness. Int. J. Solids Struct. 99, 12–27 (2016)
Demir, M.H.; Yigit, F.: Thermoelastic stability analysis of solidification of pure metals on a coated planar mold of finite thickness. Metall. Mater. Trans. B 48(2), 966–982 (2017)
Anyalebechi, P.N.: Undulatory solid shell growth of aluminum alloy 3003 as a function of the wavelength of a grooved mold surface topography, In: Anyalebechi, P. (ed.) Materials Processing Fundamentals, TMS (The Minerals, Metals and Materials Society), pp. 31–47 (2007)
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Demir, M.H., Yigit, F. A Theoretical Heat Transfer Model for Unidirectional Solidification of Pure Metals on a Coated Sinusoidal Mold with Constant Boundary Temperature. Arab J Sci Eng 44, 5825–5837 (2019). https://doi.org/10.1007/s13369-019-03736-7
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s13369-019-03736-7