Table of contents

5^th International Conference on Advances in Solidification Processes (ICASP5)

5^th International Symposium on Cutting Edge of Computer Simulation of Solidification, Casting and Refining (CSSCR5)

June 17-21, 2019

The Pitter Event Center, Salzburg, Austria

The fifth International Conference on Advances in Solidification Processes (ICASP5) and the fifth International Symposium on Cutting Edge of Computer Simulation of Solidification, Casting and Refining (CSSCR5) are held as a joint event in Salzburg, Austria, on June 17-21, 2019. The conference location, Salzburg, is known as the birth town of Wolfgang Amadeus Mozart, the UNESCO World Heritage city, at the heart of Europe. Solidification science and technology deserve the destination as we, experts in the field of solidification, place it as high as a Wolfgang Amadeus Mozart's partition.

History in brief. The conference series ICASP started in Stockholm (Sweden) in 2005, continued in Graz (Austria) in 2008, Aachen (Germany) in 2011, London (UK) in 2014. The conference series CSSCR started in Osaka (Japan) in 1999, continued in Sapporo (Japan) in 2010, Stockholm (Sweden) in 2013, Xi'an (China) in 2016.

Statistics. The joint event ICASP5-CSSCR5 attracted over 200 participants from 29 countries worldwide. From 255 abstracts received, the final program included 158 oral presentations (including 11 plenaries, 9 keynotes and 18 highlights) and over 60 poster presentations.

Topics and highlights. The joint event ICASP5-CSSCR5 covered a broad spectrum of solidification related topics. There were 27 parallel sessions, dealing with nucleation and grain refinement, in-situ observation and experimental characterization of microstructure (primary dendritic, eutectic and peritectic, intermetallic and composites); numerical modelling at different length scales (atomistic, microscopic, mesoscopic and macroscopic), casting processes (continuous casting, ingot, shape casting, electroslag remelting, ...) and cast alloys (steel, cast iron, aluminum, etc.), thermo-mechanics and properties. For the first time of this conference series, a new topic, additive manufacturing, with two parallel sessions was added to the program. Freeze casting was also for the first time introduced. The plenary lectures were carefully defined while accounting for the recommendations of the International Scientific Committee. They covered an historical review on the development route leading to modern solidification science, progress in the microstructure modelling which focuses on bridging different length scales, in-situ observation of metal alloy solidification, discussions on the facing challenges such as the missing physical properties and coupled flow-structure mechanics in solidification, and interdisciplinary research bridging solidification science beyond metallurgy.

Proceedings. After the peer-review procedure, 84 articles were included in the proceedings. Each article was reviewed, heavily relying on the members of the International Scientific Committee or senior authors. The proceedings were published before the conference.

Acknowledgments. The editors and the conference chairmen gratefully acknowledge the International Scientific Committee for promoting the conference, proposing topics of plenary lectures, and reviewing the papers. Special thanks go to ASMET, The Austrian Society for Metallurgy and Materials, for taking the responsibility of the conference organization.

Charles-André GANDIN

MINES ParisTech, France

charles-andre.gandin@mines-paristech.fr

Menghuai WU

University of Leoben, Austria

menghuai.wu@unileoben.ac.at

All papers published in this volume of IOP Conference Series: Materials Science and Engineering have been peer reviewed through processes administered by the proceedings Editors. Reviews were conducted by expert referees to the professional and scientific standards expected of a proceedings journal published by IOP Publishing.

Selective Laser Melting (SLM), the most popular metal additive manufacturing (AM) process, is well suited for making complicated parts which are difficult to manufacture by conventional manufacturing techniques. Currently, the main bottlenecks inhibiting the usage of the Selective Laser Melting (SLM) parts include the problems, such as porosity, low resolution, low surface finish quality and low build rate. In order to overcome the aforesaid problems, latest SLM machines are now being equipped with laser having small spot radius for enhanced resolution and surface finish, and high power to increase the build rate. The combination of high power and small spot radius leads to high energy density, exceeding the threshold value, resulting in transition of melting mode in the SLM process from conduction mode to keyhole mode and a formation of porosity due to collapsing of keyhole. In this study, high fidelity particle scale model is developed using open-source codes LIGGGHTS and OpenFOAM to understand the formation of porosity and to describe the physical phenomena (convection, melting, evaporation and solidification), melt flow dynamics and melting mode transition occurring in the SLM process.

Laser Beam Melting (LBM) processes benefit from significant progress in recent years. Currently, manufacturing of ceramic parts for applications at high temperature in aeronautical industries can be planned. However, understanding of defect formation is required in order to optimize manufacturing strategy. In this work, level-set modelling is proposed to simulate tracks development during LBM processes. Thermo-mechanical solution is performed in both powder and dense domains. Fluid flow is computed considering the surface tension and Marangoni forces. In addition mechanical resolution is achieved to investigate stress evolution in the rear part of the track. Applications are developed on alumina material. The influence of laser power, scanning velocity and physical properties are investigated and discussed. Validations of the heat source model are proposed by comparisons of melt pool dimensions and shapes with experimental measurements. A coherent evolution of the track morphology is shown when varying process parameters or material properties.

Understanding the dynamic evolution of primary dendritic spacing in the laser melt pool is significant from a technological viewpoint because primary spacing is one of the foremost parameters that control the final mechanical properties of additive manufactured products. In this work, a multi-scale computational framework that couples FEM and a developed quantitative phase field method is employed to simulate the evolution of microstructure and primary spacing of a nickel-based superalloy during wire and laser additive manufacturing (WLAM) solidification. Transient conditions in the laser melt pool are considered in which both temperature gradient G and solidification speed V_P are made time-dependent. Through the use of this model, the dendritic morphology, tip velocity and spacing evolution during the solidification are investigated to provide the relationship between the laser processing parameters and the final spacing. Moreover, we attempted to clarify the intrinsic mechanism of spacing adjustment under different laser processing parameters from a novel perspective. This work provides meaningful understanding of spacing evolution in nickel-based superalloy and demonstrates the potential of controlling the complex microstructure morphologies and final primary spacing during wire and laser additive manufacturing process.

A set of single track laser melting experiments was performed in a selective laser melting (SLM). The tracks were done on an Inconel 718 plate with various laser scan velocities at a constant laser power of 150 W. The geometries of the molten pool (MP), as well as the solidified dendrite structures, i.e., primary and secondary dendrite arm spacing (PDAS and SDAS), in the cross sections of the molten path were characterized to evaluate the effect of the laser scan velocity during SLM. Moreover, the local solidification thermal conditions (cooling rate R*, tip growth velocity V* and temperature gradient G*) at the MP bottom were deduced from the SDAS and the geometries of the molten pool. Finally, the mesoscopic envelope model was used to simulate the PDAS selection of the columnar dendrite growth in the molten pool. The simulated results were compared with the experimental data, and a good agreement was achieved under different laser scan velocities.

Interest has recently emerged for the manufacture of aeronautical parts by Laser Beam Melting (LBM) additive process. This energy efficient process can for instance be used to build complex geometries, which cannot be made with traditional processes. However, complex phenomena occur during powder melting and track development : vaporisation phenomena influence laser-matter interaction by creating metal vapours that are responsible for the reduction of absorbed energy. The recoil pressure generated by the vaporisation counteracts the surface tension between the melt pool and the inert gas, also inducing liquid instabilities. The study of laser-matter interaction and induced phenomena can help understand the origin of defects such as porosities or cracks. In this approach, a level-set modelling of the LBM process at a mesoscopic scale is proposed to follow melt pool evolution and track development during build. A volume heat source model is used for laser/powder interaction considering the material absorption coefficient. A surface heat source is used to take into account the high laser energy absorption by dense metal alloys. An energy solver is coupled with thermodynamic database and pre-determined solidification path. Shrinkage during consolidation from powder to liquid and compact medium is modelled by a compressible Newtonian constitutive law. An automatic remeshing adaptation is also used to save time and avoid high computational cost. In the future, the computation of multiple beads or the build of a wall in a context of lattice structures will have to be considered.

Niobium silicide-based composites, in the application of gas turbine blades, promise significant efficiency improvements compared to current Ni-based alloys. The higher temperature capability would allow the engine to run at a higher temperature than that of current alloys, increasing engine efficiency. Nb-Si based composites possess a lower density, due to the presence of ceramic phases such as Nb₅Si₃ and/or Nb₃Si. This would reduce the weight of the rotating blades. However, improvements in certain properties, such as room temperature toughness and oxidation resistance are needed.

This study focuses on the manufacturability aspect of the powder feeding laser additive manufacturing (LAM) process to engineering Nb-Si based alloy samples. LAM has the advantage of forming near-net shapes without the use of expensive cores and moulds for the reactive Nb-Si melt. Fine microstructure and even chemical composition distribution with reduced macro-segregation are obtained. With the use of power feeding system, new Nb-Si based alloys are LAMed with varying atomic composition. Microstructures of the LAMed alloys will be presented, and the relationship between the microstructure and the alloy chemistry will be reported.

Directional solidification is a favored process to manufacture homogeneous microstructures which lead to macroscopically unique properties for a material. The dependence of the spacing and type of the arising microstructure from the solidification velocity for constant velocities is extensively investigated. However the effect of changes in the solidification velocity on the resulting microstructure adjustment processes is still unclear. Therefore large-scale (3D+t) simulations of the ternary eutectic system Ag-Al-Cu with changing solidification velocities are conducted with a phase-field model based on the grand potential approach. To study the spatially complex rearrangement process during velocity changes in statistical representative volume elements, simulations with different velocity profiles are calculated in large-scale domains. The results show, that the evolving microstructure continuously rearranges by splitting and merging of the rods despite constant growth conditions. By increasing the velocity, the microstructure refines by splitting of the Al₂Cu phase. Whereas by decreasing the velocity, the microstructure coarsens by overgrowing events of both intermetallic phases.

The solidification path and the σ-phase precipitation mechanism of UNS S31254 alloy were studied on the basis of directional solidified experiments accompanied by scanning electron microscopy observations and energy dispersive X-ray a nalysis. The resulting temperatures of solidification paths and phase transformation were compared with Gulliver-Scheil and equilibrium calculations predicted using ThermoCalc^© software. It was confirmed that the experimental solidification path was in agreement with the thermodynamic calculations. The complementarity of the results have made it possible to propose a solidification path and a σ-phase precipitation mechanism for the UNS31254 steel.

The carbide precipitation nature of an automobile gear material, i.e. Fe-C-Mn-Si-Cr-Mo alloy, during carburization and element addition process are investigated through PE+PA+LR prediction. Results show that, carburization process greatly increases the amount of cementite as well as the hardness index at the surface part. Besides, the addition of Ti and V helps to formation of TiC and (V, Mo)C carbides but suppress the precipitation of cementite, which contributes equivalent hardness at surface and lighter weight to the alloy.

We present an experimental investigation on the effects of the interphase energy anisotropy on the formation of three-phase growth microstructures during directional solidification (DS) of the β(In)–In₂Bi–γ(Sn) ternary-eutectic system. Standard DS and rotating directional solidification (RDS) experiments were performed using thin alloy samples with real-time observation. We identified two main types of eutectic grains (EGs): (i) quasi-isotropic EGs within which the solidification dynamics do not exhibit any substantial anisotropy effect, and (ii) anisotropic EGs, within which RDS microstructures exhibit an alternation of locked and unlocked microstructures. EBSD analyses revealed (i) a strong tendency to an alignment of the In₂Bi and γ(Sn) crystals (both hexagonal) with respect to the thin-sample walls, and (ii) the existence of special crystal orientation relationships (ORs) between the three solid phases in both quasi-isotropic and anisotropic EGs. We initiate a discussion on the dominating locking effect of the In₂Bi–β(In) interphase boundary during quasi steady-state solidification, and the existence of strong crystal selection mechanisms during early nucleation and growth stages.

In aluminium alloys, iron is a common impurity as it is unavoidably picked up in practice. The excessive Fe is strongly prone to form various intermetallic phases. These Fe-rich intermetallics are generally brittle and act as stress raisers to weaken the coherence with Al matrix, therefore decreasing elongation. However, Fe addition in Al-Mg alloys may be beneficial because of the improvement in the yield strength with the scarification of ductility of die-cast aluminium alloys. The morphology of intermetallic phases has a vital effect on the properties of aluminium alloys. In the present work, the 3D morphology of Al₆ (Fe, Mn) in die-cast Al-Mg-Mn alloys with different levels of Fe contents were revealed. The formation of Al₆ (Fe, Mn) was also studied through crystal features and solidification behaviours.

Retained free energy drives the transformation from metastable to stable phase during double recalescence of steel alloys. Statistical methods were used to identify the mechanism controlling cluster growth based on the principle of microstructural reversibility. Application of the coefficient of determination during optimization procedures showed that an extrinsic mechanism controls nucleation and that negligible healing occurs such that retained free energy from primary phase undercooling and melt convection enhance secondary nucleation.

For a long time, the γ phase in metallic alloys has seemed to be produced through a peritectic reaction between the δ and liquid phases. However, direct observations have shown that a massive-like transformation, in which the δ phase transforms into the γ phase in the solid state, is dominant during or after solidification of the δ phase in carbon steels. To characterize such massive-like transformation, we use time-resolved tomography (4D-CT) to demonstrate the volume change during cooling from the melt and the crystallographic orientation relationship between the δ and γ phases. The volume changes from solidification and from the massive-like transformation from the δ to the γ phase were −3% and −0.5%, respectively. The transformation from the δ to the γ phase finished quickly, as demonstrated by the volume change. Fine γ grains were produced even in a single δ grain through the massive-like transformation. Also, the refined γ grains showed a wide crystallographic distribution.

The current work, describes a numerical methodology to obtain deeper understanding of the kinetics of solidification and the dynamics of Al melt infiltration into porous iron preforms, in order to develop a near net shape process for a new class of highly advanced ductile and fine grained Fe-Al intermetallic. Investigations on macroscale simulations revealed that certain pressure and wetting conditions are beneficial for infiltration into finer structures. Microstructure showed a dependency of the solidification process on diffusion. Estimates for infiltration and solidification times are developed to determine which structures can be infiltrated before solidification stops melt flow.

This study aims in combining the material properties and numerical modelling techniques through practical application to provide understanding of surface edge cracking caused by V(C, N) precipitation to enhance the yield of the continuous bloom caster at ArcelorMittal Duisburg. The investigation for this work is carried out on three different micro-alloyed steel grades; one of them being the most crack sensitive 20MnV6. A process model is used which calculates the solidification process of the strand to design an optimum cooling strategy. Therefore, two cooling patterns are employed for the steel grade 20MnV6. Reduction of area values of the steel grades 20MnV6, 27MnSiVS6 and 38MnSiVS5 evaluated from hot tensile tests using a Gleeble simulator have been used as an indication in assessing steel's cracking behaviour. Further precipitates have been analysed by SEM at ArcelorMittal. These laboratory results suggest that precipitation kinetics of V(C, N) influences the crack sensitivity of the micro-alloyed steel. The software MatCalc^® is used to simulate precipitation for process parameters of continuously cast blooms at Arcelor Mittal Duisburg as well as the parameters of the Gleeble experiments. From these simulations the Zener pinning force (ZPF), resulting from V(C, N) particles on grain boundaries, is evaluated which can be used as a measure for the crack sensitivity. Using the values of the ZPF it is possible to identify the set of casting parameters of the steel grade 20MnV6 which lead to the minimum crack intensity on the surface of the blooms. Moreover it is possible to make a ranking list with respect to the ductility drop occurring in the Gleeble experiments for the analysed steel grades. The proposed statement is an issue for a continuing investigation of precipitation modelling.

An experimental device conducts thermal analysis and volume change measurements in a single ceramic cup with cast iron quality as the variable. The recorded data are processed using specialized software. Experiments compare solidification patterns for white [WI], grey [GI] and ductile [DI] irons, to correlate the most important events between the cooling curves and contraction curves, to evaluate the sensitivity to shrinkage formation. All of the irons have similar values for initial expansion up to the start of eutectic freezing [0.437 – 0.443%]. Graphite formation promotes expansion [WI-0.002%, GI-0.109%, DI-0.596%], resulting a difference in the reached maximum expansion [WI-0.465%, GI-0.552%, DI-1.032%], placed between the end of eutectic recalescence and the end of solidification. Higher graphite expansion, greater the shrinkage sensitivity: open shrinkage increased while the density of a casting when considering total shrinkage and micro-shrinkage formation decreased. Prolonged graphitization at the beginning of eutectic reaction increased the expansion and, consequently, shrinkage sensitiveness. More graphite formation at the end of this stage also increased expansion, but this phenomena contributed to reduce of shrinkage level, due to the better access of liquid iron to compensate contraction holes. Special metallurgical treatments can favour a strong graphitization process at the end of solidification, with beneficial effects on the castings soundness.

Graphite degeneracy in heavy-section spheroidal graphite cast irons is mostly associated with the formation of chunky graphite which consists of large eutectic cells with interconnected graphite strings. At low level, appearance of chunky graphite is limited to its non-aesthetic effect on machined surfaces, while at higher level it is detrimental for mechanical properties of the components. Chunky graphite is often related to high silicon levels and too high cerium additions during the spheroidization treatment. The appearance of this defect may be limited by controlled additions of antimony that is thought to tight the excess of cerium, but other impurities and low level elements may have to be considered during melt preparation. This contribution proposes a review of recent results and approaches on chunky graphite appearance, primarily but not exclusively in the case of heavy-section cast irons. Based on this literature review and series of experimental data, a predictive index for evaluating the risk of chunky graphite appearance is proposed. Lines for further research work aimed at a better understanding of graphite degeneracy are finally suggested.

The study is focused on the influence of solidification thermal parameters upon the evolution of the microstructure (either cells or dendrites) of an Al-3wt%Mg-1wt%Si ternary alloy. It is well known that the application properties of metallic alloys will greatly depend on the final morphology of the microstructure. As a consequence, various studies have been carried out in order to determine the ranges of cooling rates associated with dendritic-cellular transitions in multicomponent alloys. In the present research work, directional solidification experiments were conducted using either a Bridgman (steady-state) device or another device that allows the solidification under transient conditions (unsteady-state). Thus, a broad range of cooling rates (), varying from 0.003K/s to 40K/s could be achieved. This led to the identification of a complete series of cellular/dendritic/cellular transitions. For low cooling rate experiments, low cooling rate cells to dendrites transition happens. Moreover, at a high cooling rate, a novel transition from dendrites to high cooling rate cells could be observed for the Al-3wt%Mg-1wt%Si alloy. Additionally, cell spacing λ_C and primary dendritic spacing λ₁ are related to the cooling rate by power function growth laws characterized by the same exponent (-0.55) for both steady-state and unsteady-state solidification conditions.

On earth, gravity-related phenomena are unavoidable, such as thermo-solutal convection caused by density gradients in the melt and buoyancy when the liquid phase is denser than the solid phase. Such phenomena can drastically affect both the grain density and their morphology during equiaxed solidification processes. For these reasons, fundamental studies comparing the influence of solidification parameters with and without gravity effects are important to obtain benchmark data, which are useful to understand and then control the final structure of materials in industrial processes. In the present work, the impact of the solidification parameters on the dendritic grain structure formation and on the final grain size and shape was investigated in situ by using X-radiography for different growth orientations with respect to gravity. In a first step, experiments were carried out with various solidification parameters and with the furnace in horizontal position, with the main surface of the sample being perpendicular to gravity to limit gravity-related phenomena. In a second step, experiments were carried out with identical solidification parameters but with the furnace in a vertical position, and for two solidification directions (upward and downward). A comparative study between horizontal and vertical experiments was carried out. Phenomena related to gravity have been highlighted and their respective impact on the solidification front propagation was analysed.

The fragmentation of dendrites immediately following the recalescence phase of growth during the solidification of undercooled melts has been invoked to explain various rapid solidification microstructures. Despite this, little direct evidence of such a fragmentation process usually survives in the as-solidified material. We report on the rapid solidification of the single phase, congruently melting intermetallic β-Ni₃Ge. During equilibrium solidification this material solidifies to the chemically ordered L1₂ crystal structure. Conversely, during rapid solidification, disorder trapping results in solidification to a random fcc solid solution, thereby providing a means to distinguish the rapidly solidified structures. We present results which show a range of microstructures in which the dendrite fragmentation process has been captured in progress. Results from EBSD Euler mapping reveal that dendrite fragmentation is a potential, but not particularly efficient, route to grain refinement.

Near eutectic Al-Cu droplets were rapidly solidified by Impulse Atomization. A wide range of microstructural scales was obtained at different cooling rates and undercoolings. The micrographs of the investigated samples revealed two distinct zones of different structural morphologies: An undulated eutectic morphology developed during recalescence following the single grain nucleation and a regular lamellar eutectic morphology resulting from the solidification of the remaining liquid post recalescence. The volume fraction of each zone was measured as a function of the droplet diameter, and the nucleation undercooling was deduced using the hypercooling limit equation. Scanning Electronic Microscopy imaging and microhardness measurements were used to evaluate the microstructural scale, and mechanical properties.

Under a NASA (National Aeronautics and Space Agency)-ESA (European Space Agency) collaborative research project, MICAST (Microstructure formation in casting of technical alloys under a diffusive and magnetically controlled convection conditions), three Al-7wt% Si samples (MICAST-6, MICAST-7 and MICAST2-12) were directionally solidified at growth speeds varying from 10 to 50 µm s^-1 aboard the International Space Station to determine the effect of mitigating convection on the primary dendrite array. The observed primary dendrite trunk diameters during steady-state growth of MICAST samples show a good agreement with predictions from a coarsening based model developed by the authors. The trunk diameters in the terrestrial-grown equivalent samples were larger than those predicted from the model. This suggest that thermosolutal convection increases the trunk diameter of primary dendrites, perhaps by increasing their tip radius due to compositional changes.

Time-resolved in situ tomography of dendritic growth in Fe–0.45 mass% C carbon steel was performed using synchrotron radiation X-rays at SPring-8 synchrotron radiation facility (Japan) with improvement of the image quality using a physics-based filter. The voxel size of the reconstructed image was approximately 6.5 μm × 6.5 μm × 6.5 μm, and the time resolution (duration of 360° rotation) was 4 s (0.25 rps). Three-dimensional images of the dendrites were reconstructed even without image processing; however, the low contrast resolution in Fe–C alloys led to poor image quality. Consequently, it was impossible to precisely track the solid/liquid interface or evaluate the average curvature. To improve the image quality, a physics-based filter (a PF filter) was developed using a phase-field model. In the PF filter, images were retrieved in terms of interface curvature. The PF filter significantly improved the computed tomography image quality. As a result, dendritic growth was clearly observed even in Fe–C alloys. Moreover, the average curvature of the solid/liquid interface was evaluated as a function of solidification time (solid fraction). The ability to systematically characterize growing dendrites will be beneficial for modeling and simulation of solidification phenomena.

This work focuses on bimetallic casting between A356 alloy melt and profiles of AA6xxx wrought aluminum alloys through a gravity casting process, with the aim to improve the component's mechanical properties. However, combining two aluminum alloys is difficult due to the stable aluminum oxide present on the surface of the aluminum inserts and the advancing liquid melt front. The oxide layer strongly reduces the wettability between aluminum melt and solid metal. It will also prevent diffusion and formation of a metallurgical bond. In order to obtain sound metallic bonding between the two alloys, different surface treatments, including flux coating and chemical treatments of the profiles have been tested. The influences of preheating temperature and melt flow modes on the quality of the bimetallic casting have been addressed. Based on a detailed microstructure characterization of the bonding layer in the casting, by using Optical Microscopy (OM), Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDS), the solidification structure development at the interface has been discussed. Results showed that when flux coating was applied, magnesium diffused to the insert surface and prevented formation of a metallurgical bond. Without flux coating, a metallurgical bond was achieved due to slight melting of the insert surface.

For directional solidification experiments with low withdrawal rates near and even below the constitutional undercooling limit of the corresponding alloy, a sample is needed which reveals a homogeneous concentration along the sample axis. As stirring in samples of a certain length is difficult, homogenization by rapid solidification is very common. Hereby, the liquid sample is rapidly moved from hot to cold and thus fine and long dendrites with segregated inter-dendritic liquid are formed. By subsequently melting and holding the sample in a resting position within a given temperature gradient, diffusion in the liquid and enhanced diffusion in the hot solid diminishes local concentration differences. In this paper, we report on homogenization and solidification experiences with transparent organic model compounds of TRIS-NPG. During one hour of homogenization we observed (i) formation of a coarse grain structure, (ii) liquid film and droplet migration by temperature gradient zone melting, and (iii) formation and eventually disappearance of liquid channels. During solidification experiments we occasionally found liquid channels, which revealed a connection to the solid/liquid interface; liquid that rose in the channel and thus formed micro-plumes at the planar solid/liquid interface. This upwards motion is explained by solutal buoyancy of NPG-rich liquid and a possible feeding through an interconnected network of channels.

Solidification cracking is an important issue during welding, casting and some of the additive manufacturing process. In order to illuminate the failure mechanisms, solidification cracking during arc welding of steel are investigated in situ with high-speed, high energy, synchrotron X-ray radiography approach. Analysis of the in situ radiography sequence revealed the solidification cracking initiates in the weld sub-surface trailing the welding electrode at relatively low true strain of about 3.1% in the form of micro-cavities. Although both material type and bending speed influence solidification cracking, cracks propagate from the core of the weld towards the free surface along the solidifying grain boundaries was found at a speed of between 1.7 - 2.6 × 10⁻³ m s⁻¹ for three different steels. In addition, a three-stage mechanistic model for solidification cracking during welding of steel is proposed.

Observations of melting crystallites in microgravity showed unusual shape changes as melting proceeded toward extinction. When re-analyzed in 2011, shape evolution data showed needle-like crystallites becoming spheroids as they melted toward extinction, suggesting that some type of capillary phenomenon at solid-liquid interfaces was responsible for an energy release capable of spherodising particles on melting, and stimulating pattern formation during unstable crystal growth. The presence of these previously undetected energy fields was recently uncovered using phase-field simulations that employ an entropy density functional. Simulations allow measurement of interfacial energy distributions on equilibrated solid-liquid interfaces configured as stationary grain boundary grooves (GBGs). Interfacial energy source fields—related to gradients in the Gibbs-Thomson temperature—entail persistent cooling along GBG profiles, a new result that fully confirms earlier predictions based on sharp-interface thermodynamics. This study also provides new insights to improve microstructure control at reduced scales by explaining the thermodynamic fields responsible for pattern formation in castings.

An efficient model for the prediction of dendritic grain growth is developed coupling the lattice Boltzmann method for solving the transport of solute and a cellular automaton algorithm for determining the evolution of grains' envelope and the release of solute during phase change. In contrast to solving equations from the field of continuum mechanics the new model is more related to particular occasions what is more similar to the behaviour of cellular automaton algorithms. The resulting dendritic grain growth shows qualitative correctness, although the consideration of solute conservation is still missing. It is shown that neglecting proposed conditions regarding the choice of time step size can destabilize the solid-liquid interface resulting in secondary and ternary dendrite arms.

During casting, diffusion phenomena are often simplified by Lever-Rule or GulliverScheil hypotheses, thus simplifying chemical diffusion to extreme configurations. The present work proposes an extension of the Tong-Beckermann microsegregation model to multi-component alloys while considering finite diffusion in liquid and solid phases plus the effect of tip undercooling of the columnar front. The behaviour of this model is studied according the solidification conditions (growth velocity and thermal gradient) and comparison with microprobe measurements is proposed for a seven components nickel-base superalloy.

A three-phase equiaxed solidification model where macroscale heat transfer and fluid flow are coupled with microscale nucleation and dendrite growth, is applied to the simulation of the macrosegregation in binary alloy solidification subjected to the electromagnetic stirring. The investigated experimental solidification case is conducted in a cavity which has a good control of the thermal boundary conditions. The proposed model uses a double time step scheme to accelerate the solution. Electromagnetic force is introduced as a source term into momentum equation in analytical form. To account for the friction from the side walls, a 2D½ flow model is applied to a three-dimensional experimental configuration. A comparison between the results of simulation and experimental ones is made.

A 3D meso-scale discrete-element model has been developed to simulate fluid flow during dendritic solidification of steel. The model domain is a representative volume element consisting of a set of equiaxed dendritic grain envelopes along with extra-dendritic liquid channels, where the final grain shape is given by a Voronoi tessellation. Solidification of each grain is simulated via a volume average approach. The output of the solidification simulation at a given solid fraction is used as the input mesh for the fluid flow simulation. A single domain Darcy-Brinkman model is used to calculate the pressure field within the liquid channels, with Poiseuille flow assumed to occur in the extra-dendritic region, and Darcy flow assumed to occur within the dendrite envelope. Mass conservation over each element is then used to derive a flow equation that is solved via the finite element method. The results of this new model are first compared with a previously-developed granular model [1] where fluid flow only occurs between the grains, and then compared with different forms of the Carman-Kozeny equation. It is shown that the intra-dendritic liquid fluid flow plays a major role in the semi-solid pressure field, and thus needs to be included when investigating hot tearing susceptibility in engineering alloys undergoing dendritic solidification.

Molecular dynamic simulations, ab initio (DFT) calculations and experimental evidence suggests that there is a liquid-solid transition region which may be characterised by an order parameter. In this interface region the order parameter is not observed to be symmetrical, rather it tends to be steep on the solid side and exponentially decreasing on the liquid side. The order parameter in phase field computations is, to date, always assumed to give a symmetrical interface region. Hence, we ask how to extend the phase field model to give a profile that fits this data, and how such a model affects the simulation.

Within the framework of the ESA GRADECET project, experiments of directional solidification of cylindrical Ti-Al samples were conducted in hypergravity. The experiments were performed in a centrifuge with the apparent gravity (sum of centrifugal and terrestrial gravity) aligned along the cylinder centerline. 3D numerical simulations of aluminum macrosegregation in these samples are presented. A volume-averaging solidification model is used that accounts for centrifugal and Coriolis accelerations in a non-inertial rotating reference system. We compare the melt flow pattern and the macrosegregation formation under terrestrial gravity and under $20\overrightarrow{g}$ centrifugation. The results show that the Coriolis acceleration, although very weak, breaks the symmetry of the thermosolutal convection, having an important impact on the final macrosegregation pattern. The macrosegregation is entirely modified in comparison with a sample solidified under terrestrial gravity conditions. Besides the aluminum segregation intensity increases with the centrifugation level.

This paper summarizes the development of a computational fluid dynamics (CFD) model based on the commercial software package ANSYS-CFX, which has been used to examine the kinetics of dissolution of a single stationary Ti-N particle surrounded by moving liquid titanium. The model accounts for diffusional mass transport in the solid particle, the formation of a two-phase solid/liquid boundary layer and both advective and diffusional transport to the bulk liquid. The results have been used to estimate an effective mass transfer coefficient that may be applied in models that only consider solid-state mass transport of nitrogen. The results show that a correction is needed to the conventional Ranz-Marshall correlation to more accurately calculate the mass transfer coefficient during the Ti-N particle dissolution process.

Kinetics of crystal growth in undercooled melts is analyzed by methods of theoretical modeling. Special attention is paid to rapid growth regimes occurring at deep undercoolings at which non-linearity in crystal velocity appears. A traveling wave solution of the phase field model (PFM) derived from the fast transitions theory is used for a quantitative description of the crystal growth kinetics. The "velocity – undercooling" relationship predicted by the traveling wave solution is compared with the data of molecular dynamics simulation (MDS) which were obtained for the crystal-liquid interfaces growing in the 〈 100〉-direction in the Ni₅₀Al₅₀ alloy melt.

The control of the carbon macrosegregation level in steel ingots is important for the structural integrity of the final component. During solidification, the fragmentation of the columnar dendrites is an important source of equiaxed grains, and has a large influence on the macrosegregation and the grain structure. The goal of this study is to show that a numerical model that takes into account fragmentation can describe the formation of the structures and the macrosegregation during solidification of a large steel ingot. The present article describes the multiphase numerical model used in the simulations. The simulation results are compared to experimental data from a 9.8 t ingot cast in A5/6 steel by ArcelorMittal Industeel. The model can then be used to explain the formation of the observed structures. For example, we show that the structural transitions, first from columnar to equiaxed globular and then to equiaxed dendritic at the bottom of the ingot are a consequence of the concurrent transport and growth of the dendrite fragments from the columnar zone. Furthermore, we show that most of the structures are formed very early on during solidification, whereas macrosegregation develops much more gradually.

Semi-grand canonical Monte Carlo (SGCMC) simulations are performed to derive thermodynamic properties of binary alloy from atomistic-based simulations. Particularly, solidus and liquidus compositions are directly derived for Fe-Cr alloy described by two different EAM potentials. Although the SGCMC simulation can derive relationship between the free energy and composition at any temperature straightforwardly, partial phase diagram obtained from SGCMC simulations strongly depends on the choice of interatomic potential.

In this study, a numerical model was developed, and direct simulations were performed to predict solidification grain structures and macrosegregation based on a three-dimensional cellular automaton finite difference (CAFD) method coupled with flow calculation of natural convection and shrinkage flow. First, to evaluate the model coupled with natural convention, simulations of unidirectional solidification for Al-10wt% Mg alloy were performed. Mg-rich plumes rising in the melt were seen due to subsequent upward flow, and Mg-rich channels forming in the mushy zone were observed. Columnar grains were then formed, and they became coarse afterwards. Next, to evaluate the model coupled with shrinkage flow, simulations of casting Al-10wt% Cu alloy in a unique mold, which can form macrosegregation in the central region of the small ingot, were performed. The bridging of columnar grains formed during solidification, and the positive segregation was generated in the region below the bridging. Thus, the main factor for this macrosegregation is the shrinkage flow with bridging. From the comparison of simulation results with and without the chill for the unique mold, it was established that the shrinkage flow and the bridging of solidification structures play an important role in macrosegregation.

Correct prediction of composition heterogeneities and grain structure across a steel ingot is critical in optimizing the industrial processing parameters for enhanced performance. The columnar to equiaxed transtion (CET) is a microstructural transition which is strictly controlled as it affects the mechanical properties of the final product along with the macrosegregation patterns. Larger equiaxed regions are preferred for most industrial applications. CET is significantly affected by the number density of equiaxed grains and by the nucleation undercooling. 8 kg 42CrMo4 alloy steel ingots (240 mm x 60 mm x 60 mm) were cast. The cast structure was characterized by ASCOMETAL. The experiments were simulated with a process-scale model of solidification that incorporates a multiscale description of the microstructure formation. The goal of the present study is to show the capabilities of such a process-scale solidification model to explain the observed structure distributions (extent of the columnar and equiaxed zones, equiaxed-to-columnar transition).

A 3D mesoscopic envelope model is used to numerically simulate the experimental X-ray observations of the equiaxed dendritic isothermal solidification of a thin sample of Al-20 wt%Cu alloy including the natural convection flow. Several four-grain simulations are run to investigate the effect of the convection, of the grain position, and of the grain rotation on the tip growth kinetics of one of the grains. We show that the effect of convection flow – consequence of the presence of gravity parallel to the sample thickness direction, z – on the growth kinetics of the reference grain depends significantly on the position of the grain along the sample thickness.

Solidification during twin-roll casting happens by cooling of the melt between two counter-rotating rolls, where the molten alloy is constantly fed in. For an inoculated Al-melt, grain growth leads to a gradual increase of solid fraction, so that a coherent solid network forms. Depending on the process condition, this solid network might be subjected to compression within the gap between the two rolls. By using a two-phase volume average model that accounts for (i) transport and growth of spherical grains within a flowing melt, (ii) formation of a coherent solid network above a specific solid fraction and (iii) viscoplastic flow of the solid network saturated with interstitial melt during casting and compression, the process is numerically analysed. It is found that an optimum process with minimum macrosegregation can be achieved for conditions where the kissing point of the two viscoplastic semi-solid shells nearly coincides with the roll nip. It is demonstrated how casting speed, cooling intensity and strand thickness must be related to hit the optimum process window.

Due to start-up and shut-down operations of engine, TiAl structural components usually undergo not only static but also cyclic mechanical loading. The crack propagation mechanisms of γ-TiAl under two types of loading are studied in this work to reveal the differences of the mechanisms under constant strain rate and cyclic loading. Since the crack prefers to nucleate at the interface, two types of loadings are applied to a γ-TiAl interface system with a pre-existing micro-crack at the interface by the means of classical molecular dynamics simulation, the loading direction is along [111] perpendicular to the interface. The evolution of crack tip and dislocation is observed in atomistic scale. The results show that, under both loading types, the crack propagates asymmetrically, Shockley dislocations emit on the (-1-11) slip plane from the right crack tip and slip along [-1-1-2] direction. The dislocations blunt the extension of crack while the left crack tip propagates in a brittle way. During the cyclic loading, different with constant strain rate condition, the crack advances and dislocations slip with increasing loads and retreat during unloading. In addition, the stress decreases and the crack length increases with the increase of the cyclic loading number.

The Interdependence model [1] predicted that nucleation would occur in waves of events with regions of no nucleation in between each wave. The waves continue to form until nucleation covers the sample. The cause of this phenomenon was attributed to the formation of a nucleation-free zone which incorporates solute suppressed nucleation and inhibited nucleation zones. Recent real-time synchrotron x-ray studies by Prasad et al [2], Liotti et al [3] and Xu et al [4] have confirmed this hypothesis showing nucleation occurs in a step-wise fashion with a number of events occurring followed by little or no nucleation for a short period before another set of events occurs. A microscale solidification model that predicts diffusion-controlled dendritic growth has successfully shown the effect of the developing constitutional supercooling on the selection of nucleation events. In this study, we use this model to predict the solidification behaviour under the conditions experienced during these real-time synchrotron studies.

Recent theories suggest the existence of an incubation time, over which a liquid alloy prepares for nucleation by decomposing into compositional fluctuations. Accordingly, in a recent work by the present authors, the solidification path of a Controlled Diffusion Solidification (CDS) mixture was calculated. The calculated CDS path begins at a higher liquidus temperature comparing to conventional solidification and the fraction solid values are achieved at a relatively higher temperature. To provide information on the CDS mechanism and physical structure of the CDS mixture in the mushy zone, Al-7.8Zn-2.6Mg-2Cu alloy was solidified, in this study, via conventional and CDS process in the presence and absence of recalescence. Typical grain structures obtained via the two solidification conditions is characterized using Electron Back Scattered Diffraction. Results showed that the nucleation continues to occur in the presence of recalescence, while it is suppressed in its absence. According to the two step nucleation theory, the increase in the nucleation temperature causes sufficient recalescence in the mixture, allowing the unnucleated liquid phase to decompose into chemical fluctuations and prepares for further nucleation. As a result, in the presence of recalescence, nucleation in a CDS mixture is not as readily halted as during the conventional solidification, which is in contradiction with the recent theories developed based on the classical theory of nucleation.

The present contribution reviews the recent progress related to the influence of Icosahedral Short-Range Order (ISRO) and icosahedral Quasicrystals (i-QC) formation on the solidification of fcc alloys through minor solute element additions. From intensive crystallographic analysis of multi-twinned regions in as-cast Al-based and Au-based fcc alloys, Kurtuldu et al. have shown recently that a so-called "iQC-mediated" nucleation mechanism occurs when a few hundred ppm of Cr and Ir, respectively, are added to the melt [1] [2]. Similarly, it appears that the growth directions of dendrites in Al-Zn:Cr is also influenced by ISRO in the liquid, thus showing an attachment kinetics effect [3]. In a recent contribution, we have shown that iQC-mediated nucleation also occurs in pink gold alloys with Ir-additions, but two additional phenomena at high solidification speed [4]: (i) a spinodal-type decomposition of the liquid, leading to the formation of twinned Cu precipitates in addition to multi-twinned Au-rich grains; (ii) a change of the microstructure of the Au-rich grains, from 〈100〉 dendrites to 〈111〉 textured cells in the columnar zone.

Isomorphic inoculation has recently been introduced by the authors as a successful method to grain refine cast titanium aluminides [1]. Analyses of the cast grain size together with introduced particle size distributions revealed anomalously high grain refinement efficiency which was attributed to the particles breaking up during the holding stage prior to solidification [2]. In the present work, the microstructure of the inoculant powders is investigated in both the cryo-milled state as well as after simulated thermal cycles to reproduce their heating and holding in the melt. Results show that milling time does not impact the grain size in the particles, only their size distributions. Heat treatments between 1500 and 1600°C for short periods of time allowed the activation energy for grain growth and evaluation of the grain size evolution in the particles during the isomorphic inoculation process to be determined. Assuming that grain boundary melting is the predominant break up mechanism, a model to estimate dissolution of the powders is presented which includes diffusion and fluid flow. Despite its relative simplicity, the predicted number of particles remaining after heating and holding, which lead to grains in the as-cast structure, are in good agreement with the measured grain size. Finally, the paper summarizes the main features and mechanism making isomorphic inoculation a promising route for grain refining as-cast alloys.

Since it is not straightforward to directly observe nucleation at the initial stage of solidification in experiments, investigation from computational approach is strongly desired. In this study, influence of grain refiner in heterogeneous nucleation of undercooled Al melt is investigated by molecular dynamics calculations. Particularly, we focus temperature, size of the refiner, and anisotropy in surface orientation of the grain refiner. It is confirmed that the growth rate of FCC Al at the (0001) plane is much larger than that at the other surfaces at all temperatures calculated in this study. Moreover, epitaxial growth of HCP Al appears on the surface of $(10\bar{1}0)$ and $(11\bar{2}0)$ planes at large undercooling temperature.

It has been reported that native MgO particles in Mg alloy melts can act as heterogeneous nucleation substrates such that grain refinement of Mg alloys is achieved. A recent study showed the addition of Ca, combined with the native MgO particles, significantly improves grain refinement of Mg and its alloys. However, the mechanism underlying the grain refining phenomenon is not well understood due to the lack of direct experimental evidence. In this work, we investigated the segregation of Ca atoms at the Mg/MgO interface and its effect on grain refinement in Mg-0.5Ca alloys by utilizing advanced analytical electron microscopy. The experimental results focus on the chemical and structural information at the interface between MgO and the Ca solute. Adsorption layers rich in Al, N and Ca have been detected on {1 1 1} facets of MgO particles, with the lattice structure resembling the structure of MgO. It is suggested that the significant grain refinement improvement can be attributed not only to the growth restriction due to the presence of Ca addition but also to the specific chemistry and structure of the adsorption layers.

A homogeneous microstructure of as-cast magnesium alloys is desired to improve the formability during their subsequent thermomechanical processing. Owing to its similar crystal structure to Mg, the part of Zr formed by peritectic reaction during solidification was considered to be the most effective nucleants for alpha-Mg. However, regarding the Al-containing magnesium alloys, up to now no suitable and effective external nucleants were found for them. Recently, it was demonstrated that the additions of SiC worked in refining both the Mg-Al and Mg-Zn alloys. The SiC particles acted as nucleants in magnesium alloys are attracting more attentions. The present work investigated and compared the effects of external SiC particle additions on the grain refinements of Mg-Al and Al-free Mg-Zn (Mn) alloys. Their microstructures were characterized using XRD, SEM and TEM. It was found that the additions of SiC particles could refine the grains of both Mg-Al and Mg-Zn alloys. The SiC particles cannot act as a direct heterogeneous nucleant for the nucleation of alpha-Mg in both Mg-Al and Mg-Zn (Mn) alloys. The responsible mechanisms for their grain refinements are different. Regarding for Mg-Al alloys, the grain refinement caused by the addition of SiC particles is attributed to the formation of a ternary intermetallics Al₂MgC₂, which has a very similar crystal structure to that of Mg. As for Mg-Zn (Mn) alloys, the grain refinement is attributed to the formation of a (Mn, Si)-enriched intermetallics by the interactions between SiC and impurity Mn in alloys.

Ultrasonic processing (USP) during direct-chill (DC) casting of light metal alloys is typically applied in the sump of a billet. This approach, though successful for structure refinement and modification, has two main drawbacks: (a) mixture of mechanisms that rely heavily on dendrite fragmentation and (b) a limited volume that can be processed by a single ultrasonic source. We suggest moving the location of USP from the sump to the launder and applying it to the melt flow for continuous treatment. The apparent benefits include: (a) degassing of the melt volume, (b) grain refinement through activation of non-metallic inclusions, fragmentation of primary crystals, and deagglomeration of grain refining substrates, and (c) a possibility to use a single ultrasonic source for processing large melt volumes. To optimize this process with regard to the acoustic intensity and melt residence time in the active cavitation zone, flow modification with baffles as well as informed location of the ultrasonic source are required. In this paper, we demonstrate the results of experimental trials where the degassing degree and grain refinement have been the indicators of the USP efficiency for two aluminium alloys, i.e. LM25 and AA7050. The results are supported by acoustic measurements and computer simulations.

Advanced numerical simulation models for continuous casting of steel were developed in Finland by Casim Consulting and Aalto University in cooperation with the University of Oulu and the steel industry. The aim was to develop models that are scientifically rigorous, but also computationally fast enough to be used in online applications. The models developed are a transient three-dimensional heat transfer model, CastManager, and a solidification and microstructure model, IDS. The computing time of these models are short, and they are integrated together in one online concept. This concept is installed in the automation systems of four slab casters in Finland. Testing and validation work is in progress. The system simulates the important heat transfer, solidification and microstructural phenomena in continuous casting online. The future aim is that this information will be used for online quality control and for optimizing the process conditions to avoid formation of defects. Many quality indices have already been developed. A steady state version of the CastManager tool has also been developed, called Tempsimu.

Computational process modelling has become an important engineering tool in the casting industry to predict the solidification sequence in complex castings. Used properly, this tool can help reduce manufacturing costs. One of the challenging issues in developing casting simulations of the low pressure die casting (LPDC) process for automotive wheels is to quantify the heat transfer coefficients (HTC) within the cooling channels in a die. When water is used as the cooling media, the HTCs exhibit a complex, non-linear behaviour due to the boiling phenomena that occur making it possible to extract a significant amount of heat from the die in a short period of time and influence the solidification of a wheel. Primarily, constant heat transfer coefficients have been used to describe this heat transfer in casting models up until now, but an opportunity exists to improve the transient description of heat transfer in channels cooled with water. In this paper, HTC's in a lab-scale physical analogue model of die cooling will be characterized as a function of initial die temperatures.

The alloy casting process is one of the major manufacturing processes to produce near net shape components. The casing process is prone to a wide variety of defects, with hot tear being one of the most detrimental. The two main factors generally recognized as the primary cause for formation of hot tears are the mechanical response of the mush (which effects its permeability), and the solidification range (solidification time). The response of the mushy zone under deformation is mainly affected by the solid fraction, strain rate and grain morphology. Even though the science behind the formation of hot tear is understood, there is no general criterion to quantify the hot tear formation under varying casting conditions. The development of ultra-fast X-ray imaging has facilitated the means to quantify the effects of the critical parameters in-situ and develop better correlations for hot tear prediction. The in situ experiments will also provide insights into mush rheology, which has significant influence on hot tear formation. In this study, isothermal semi solid compression studies of Al-Si-Cu alloys were carried out using specially built thermo-mechanical rig. We studied the effects of the strain rate in the range of 2 × 10^-4–0.02/s and solid fraction (∼0.6-0.9) on the mechanical response of the mushy zone. The sample were characterized before and after deformation using X-ray micro tomography. The data was subjected to an image processing routine and the amount of porosity and hot tear was quantified. The stress-strain curve of the semisolid alloys showed a characteristic strain softening behaviour for semi solid samples with ∼0.6-0.7 solid fraction, irrespective of loading rates, whereas the behaviour at higher fractions were that of constant flow stress. Additionally, in situ compression experiments were carried out, wherein the liquid channel thickness at various strain values were measured. Isolated liquid channels were formed under loading, from where the hot tears were found to nucleate. Hot tear susceptibility was found to increase with increasing strain rate and rheology of the mush, which is dependent on solid fraction.

Chills are used in the production of metal castings as a thermal aid to promote directional solidification in casted sections. This study will review microstructure and thermal circumstances of the internal chill interface where the chill is intended to be incorporated into the structure of the cast section. The conditions for interface coherency of cast steel sections from 25 to 50mm will be shown. Solidification proceeds away from the interface chill growing to a maximum thickness and then melting back to the original chill geometry. Furthermore, it is shown that promoting section solidification prior to the complete melting of the internal chill can lead to the formation of interfaces will be coherent across the chill and cast sections for compatible steel alloys. A computer model of the heat transfer and interface evolution show the possibility of using the coherent interface of internal chills in the design of other cast components.

One of the crucial ingredients of today's numerical simulation technologies is their cross-scale and cross-platform capabilities for material processes applications. Handling of simultaneous evolution paths at various scales\times (i.e., multi-scaling) during complex material processes where materials microstructure & microchemistry interact with meso and macro events, is one of awkward challenges of computational material engineering. The material phase change and also its thermal energy evolutions are also drastically increasing the complexity of the numerical simulations. The introduction of multi-resolution and multi-scale numerical schemes in recent years and their ground-breaking potentials for computational material science applications have vividly raised the expectations for more resourceful future virtual tools. A crucial point in implementing these novel numerical techniques for simulation of material processes is their flexibility towards the modelling approach (i.e., discrete, continuous...) and also their compatibility with solver-independent platforms. As these multi-resolution\physical techniques should provide some answers to the best ways of designing future high-performance materials along with optimisation of new & existing material processes and also improvement of their life-time performance, a broad & well-structured research work is required. Hence, the proposed multi-resolution framework herein, has been developed based on analytical & numerical techniques built on sound physical and mathematical foundations developed during the last few decades. The combination of recently developed concepts of dynamic\evolving domains along with cross-scale grid overlapping\interfacing and also sound parallel computing routines have been employed to address the multi-scale challenges of material processes simulations. In the research work herein, analytical and computational aspects of multi-resolution simulation framework for dynamic casting processes (i.e., continuous and semi-continuous casting) are presented and physical\mathematical basis of the analytical-computational solidification and cooling modules are elaborated. Industrial applications of the techniques are also envisaged using parallel-processing and fast computing facilities for full-scale casting applications.

This paper reports on the development of Solidification Continuous Cooling Transformation diagrams that relate the solidification paths to the inherent microstructures of binary and ternary alloys. The methodology is based on the quantification of a solidified microstructure for its various phase fractions. This measured data is combined with well-established solidification models and phase diagrams to yield undercooling temperatures of individual phases. The thermal history and undercooling of different phases in the solidified alloy are estimated for a wide range of cooling rates (from 10^-2 °Cs^-1 to 10⁵ °Cs^-1). To describe the methodology, dedicated samples of Al-Cu, Al-Cu-Sc and Al-Si alloys were studied. With said alloys being solidified in a controlled manner, over a wide range of cooling rates and undercoolings, via Impulse Atomization, Electro-Magnetic Levitation, and Differential Scanning Calorimetry

In the present study, effect of cooling rate on the formation of the porosity in the thick aluminum sand casting was investigated. Nowadays large scale thick aluminum casting replaces steel frame for vacuum chamber for semiconductor production, with the consideration of weight and cost reduction. Several thick aluminum castings were manufactured using chill with temperature measurements. The castings were inspected by using 3D computed tomography in order to quantify the porosity defect density in the castings. Effect of the thickness of the chill on the porosity defect density were discussed.

The high pressure die casting process is extensively used to manufacture light metal parts with high productivity. A major drawback of the process is the relatively high variability in mechanical properties and poor repeatability between casting cycles, limiting the achievement of weight reduction through lighter design. Although it has been established that mechanical properties are adversely affected by casting defects, the origin of the relatively high randomness in the HPDC process is not well understood. Numerical simulation is a powerful and cost-effective tool to address this question, as it gives access to quantities that are difficult to obtain experimentally. A numerical simulation approach based on the finite element casting software ProCAST has been developed. The model was applied to the casting of aluminium tensile test samples, which were used to measure the tensile properties of the alloy. Simulation permitted the study of fluid flow, solidification and defect formation during each stage of the HPDC process: pouring, injection and cooling. Air entrapment and porosity distribution in the cast part were predicted. The results were compared with temperature measurements, porosity observations and solid distribution in the sleeve prior to injection. Although the results are still very preliminary, some trends could be established between the level of turbulence of the melt during injection and reduced elongation.

The accumulation of iron in molten aluminium is one of the main concerns for the recycling and casting industries because it leads to the formation of undesirable Fe-rich intermetallic compounds which are detrimental to mechanical properties. Many methods have been developed in the past to reduce the iron accumulated in molten aluminium scrap, but they all suffer from poor efficiency. Hence, a more efficient method is urgently needed to mitigate the negative effect of high iron levels in the melt, thereby avoiding downgrading secondary aluminium to low quality products or the dilution with expensive primary aluminium. This contribution provides a study of the Fe-rich intermetallic compounds developed in aluminium casting alloys with high levels of Fe as a function of melt processing conditions. Results show that the formation of the Fe-compounds is not only dependent on the cooling rate and holding time before solidification, but more on the initial melt treatment as it enhances the nucleation and growth of the Fe-phases. Elemental addition of Mn leads to the formation of large and compact intermetallic particles, but at slow rate. Physical melt treatment by intensive high shearing produces a much faster nucleation and results in a fine dispersion of smaller iron containing intermetallic particles. The latter could be used either to increase the tolerance to iron contamination or to facilitate the iron removal process, providing huge benefits for the recyclability of scrap aluminium alloys as it would allow the transformation of low-grade feedstock into a low cost and small carbon footprint material for high quality castings.

Piston Al-Si eutectic alloys are used to produce direct-chill cast billets for subsequent forging. Because of a very complex composition and multi-phase heterogeneous structure, it is necessary to control the formation of primary and eutectic compounds either through alloying or casting conditions (or both). In this study we used ultrasonic melt processing above or across the liquidus line to affect the occurrence and size distribution of primary Si as well as morphology of primary Al dendrites and high-temperature eutectic phases. The refinement of these particles has potential benefit for mechanical properties and formability during forging.

Numerical simulation of casting filling process with complex shape is time-consuming. Compared with the traditional SOLA-VOF method, the lattice Boltzmann method (LBM) calculates the pressure field by particle distribution functions instead of the correction of the velocity and pressure fields, which greatly simplifies the calculation process. In addition, the LBM provides a flexible approach which can be easily parallelized. In this study, the LBM is employed to simulate casting filling process. An implementation of a volume-of-fluid (VOF) method within the lattice Boltzmann framework is proposed to capture the free surface of the casting filling process. A Smagorinsky large eddy simulation (LES) model is adopted to improve the numerical stability of the LBM. An adaptive time stepping technique is implemented to ensure an efficient and stable simulation. The model is validated by the experimental and simulation results of Campbell box filling process. The filling process of complex casting is simulated, and the result is compared with the filling process obtained by the SOLA-VOF method. The prediction accuracy and reliability of free surface profile is analysed.

Hot isostatic pressing(HIP) is an effective method to eliminate the shrinkage in castings. The morphology of shrinkage is complex, and there are structures such as sharp corners and small passages which would lead to a large number of elements and easily divergent calculation results. Therefore, the application of numerical simulation in HIP is limited. To solve the non-convergence problem, the real shrinkage is often simplified as a sphere. However, this simplification ignores the characteristics of the shrinkage and makes the simulation results unreliable. In this paper, the technique of morphology-equivalent ellipsoid is applied to the numerical simulation of shrinkage evolution during HIP. Firstly, the 3D morphology of shrinkage in Ti6Al4V alloy castings is obtained by micro computed tomography. The radius of sphere and the geometric size and orientation of morphology-equivalent ellipsoid are calculated by corresponding equivalent techniques. Secondly, the numerical simulations of HIP for the Ti6Al4V castings before and after the equivalent method are carried out. The volume evolution of three kinds of shrinkages are recorded and compared. The results show that the volume evolution of the morphology-equivalent ellipsoid is closer to that of the real shrinkage, the feasibility of the morphology-equivalent ellipsoid and the limitations of sphere are verified.

IDS (Inter-Dendritic Solidification) is a thermodynamic-kinetic software package that simulates phase changes, compound formation/dissolution, and solute distribution during solidification of steels as well as during their cooling/heating process after solidification. The software package also simulates solid-state phase transformations related to the austenite decomposition process at temperatures below 900/600 °C, and calculates thermophysical material properties from the liquid state down to room temperature. These data are needed in other models, such as heat transfer and thermal stress models, whose reliability heavily depends on the input data. The software package also features a database for thermodynamic, kinetic and microstructure data, as well as for several material properties. Owing to the short calculation times, the IDS tool is suitable for online applications. This paper presents IDS and its modules with the latest developments and validations, along with examples of modeling results.

Band segregation has been found in the H13 die steel produced by the electroslag remelting (ESR) technology. Chemical and metallographic studies have been carried out on a one ton ESR ingot of H13 die steel, so as to understand the formation mechanism of the band segregation. The results indicate that the T.O content and S content decreased because of cleanliness improvement of ESR process. Transverse macrosegregation of S content decreased after ESR. The overall removal ratio of the inclusion is around 65.8%. The original complex inclusions would be modified to the CaO·Al₂O₃ inclusions. Al₂O₃ and MnS inclusions can be found after ESR. Both of Al₂O₃ and MnS inclusions were found to be the core of primary carbides. The net like structure in ESR ingot and banded structure in the forged steel were observed. V, Mo, Cr and S are rich in the segregation areas of ESR ingot. Besides, black and white segregation bands can be observed on the forged steel samples after etching. Uneven distribution of carbides rich in V, Mo and Cr was observed in banded structure.

Maintaining competitiveness in steel manufacturing requires improving process efficiency and production volume whilst enhancing product quality and performance. This is particularly challenging for producing value-added advanced steel grades such as advanced high strength steels and electrical steels. These grades due to higher weight percentage of alloying elements cause difficulties in various stages of upstream and downstream processing, and this includes continuous casting, wherein high solute levels are critical towards macro-segregation. Interface growth direction in systems with more than one component is dictated by the solute profile ahead of the moving solidification front. Understanding the profile of growth direction with casting process parameters during the progress of casting will provide an important perspective towards reducing the macro-segregation in the cast product. In the present study, two steel slab samples from conventional slab caster under the influence of electromagnetic brake (EMBR) at Tata Steel in IJmuiden (The Netherlands) have been investigated for dendrite deflection measurements. The samples showed a transition zone where a change in the deflection behavior occurs. Also, the magnitude of the deflection angle decreases away from the slab surface. Correlating these experimental data with modeled fluid flow profile will help in improving the understanding of the dynamic nature of the solute advancement so that the casting parameters can be optimized to improve product quality.

The targets of this study were to determine the effect of vertical location and the composition of inclusions to the occurrence of oxide–sulfide stringers, and to determine the calcium aluminate phases most prone to form stringers during hot rolling of aluminium killed, calcium treated steel. The phases present in the inclusions have a significant effect on the deformation of inclusions during hot rolling, and consequently, on mechanical properties of the steel. A MATLAB script is utilized to identify and locate detrimental stringers from the hot rolled plates. Inclusion analysis data gathered with a scanning electron microscope and exported from IncaFeature software is analyzed. The following properties are presented for each stringer: the number of inclusions and length of stringer, phase fractions and compositions, and the composition of the unfragmented inclusion before hot rolling. According to the results, the longest stringers have total lengths over 200 µm, with almost 20 inclusions. The overall composition of the longest stringers is between C12A7 and C3A calcium aluminates with minor MgO contents. The diameters of the unfragmented inclusions in the slabs, forming stringers during hot rolling, were estimated to be around 20 µm for the longest stringers. From the dataset, plenty of CaO–CaS stringers were also characterized, obviously a result of excess calcium treatment.

Previous studies have shown that it is extremely problematic to add synthetic inclusions successfully into liquid steel for clean steel experiments. Small micro-particles encapsulated in a metallic parcel are difficult to pass through the melt-gas interface and inclusions tend to agglomerate then float up to the liquid surface. In this study, powder metallurgy is used to distribute cerium oxide particles of a known size from 1µm to 14µm within a small-scale steel ingot. Carbonyl iron powder has been mixed with 0.1 wt.% cerium oxide (CeO₂) then sintered in an electrical furnace to produce sintered ingots of 500 grams. A series of induction furnace melting trials using a total of 400 grams of electrolytic iron and cerium oxide sintered ingot have been undertaken. The work has included extensive FE-SEM analysis using the INCA Feature^® to characterise synthetic cerium oxide inclusions from both the sintered ingots and trial ingots. The INCA Feature^® results showed that the size distribution and number of cerium oxide inclusions agreed well between the sintered ingot and trial ingot. The synthetic cerium oxide inclusions are homogeneously dispersed through the bottom, centre and top of the trial ingot with approximately 16 number counts/mm². Analysis suggests that more than 95% of the cerium oxide from the sintered ingot has been distributed throughout the trial ingot. The work has also been upscaled from 400 grams up to 1.5 kg and has been successful. The method developed will be useful for further studies into steel cleanness of high value alloyed steels.

Asymmetric flow of the molten steel in a continuous slab casting mold may be detrimental to the quality of the solidified end product. Depending on the severity of the biased flow, local mold powder entrainment, non-homogeneous solidification around the perimeter of the initial shell or non-optimal inclusion seclusion may occur. In particular, nozzle clogging in the last slabs before an SEN exchange may cause strong and asymmetries in the upper regions of the mold. To avoid costly downgrades of steel quality in these slabs, it is vital to maintain stable and symmetric fluid flow conditions in the mold. The EMBR and the FC Mold are two flexible electromagnetic devices able to produce asymmetric braking/stirring along the width of the mold in slab casting, and in this way allow counteraction against e.g. biased mold flow or local excessive flow speeds. Numerical computations of mold fluid flow and magnetic flux have been carried out to quantify the required fields to symmetrize biased flow scenarios caused by e.g. SEN clogging. In conjunction with steel plant trial feedback, the simulation results have been used to setup control algorithms for the EMBR and FC Mold.

One technology that is often employed in continuous casting of high-carbon steel billets to minimize centre - (or macro) segregation is hard secondary cooling. Investigations unanimously show, that hard cooling significantly reduces macro-segregation, but a mechanism for the reduced segregation is rarely given. In this paper the solidification of high carbon tire cord grade C80D cast as a 150x150 mm billet is calculated using the proprietary SMS Group solidification simulation package CHILL using steel properties calculated with the Thermo-Calc Software package and TCFE steels database. The obtained cooling rates in the billet for hard and soft secondary cooling are used to run solidification simulations considering solute redistribution using the diffusion module DICTRA. It is shown that for cooling rates achieved in continuous casting the steel solidifies far away from equilibrium. The solidification profile and solidus temperature lie in between the Scheil solidification model and the para-equilibrium Scheil model with carbon defined as a fast diffusing element. The calculated cooling rates and temperature gradients are used to simulate the solidification microstructure 20 mm from the billet surface using the phase field approach and the MICRESS® software package linked to Thermo-Calc through the TQ interface. This model clearly shows, that the most probable mechanism by which hard cooling reduces segregation is trapping of solutes between the intricately branched dendrite microstructure that results from the steep temperature gradients achieved when applying hard secondary cooling.

This paper aims to obtain fundamental information on chemical homogenisation process of liquid steel with alloy additions in the bloom tundish. For alloy feeding to liquid steel pulse step alloying method was applied. Author checked the effect of hydrodynamic conditions occurs in the internal working space of tundish on the process of alloy mixing with liquid steel. Within the work basic and proposed tundish equipments were considered. Numerical modelling technique was employed to demonstrate the process of alloy addition mixing during continuous casting process. Ansys-Fluent computer program was used for numerical simulation. For particular continuous casting strands time mixing was calculated.

The Arvedi ESP process and a variety of produced materials have been continuously developed since the opening of the Arvedi ESP plant in Cremona in 2009 to meet market demands for more sophisticated steel grades. The development of grades for more advanced applications such as advanced high strength steels and multiphase grades is of interest. Dual phase grades such as DP600 are already produced through an ESP line on an industrial scale; additional multi-phase grades such as TRIP are under development. High-strength steels for the automotive industry have especially high demands on material properties. In addition to the mechanical material properties, an excellent surface quality is required. The fundamental basis for such material properties on rolled coils needs to be provided from continuous casting. This paper deals with the classification of different – either Si - or Al-based – alloying concepts for TRIP steels with respect to their prospective behaviour in a thin slab caster.

The remelting behavior of the tempering steel 50CrMo4, was investigated with several experimental melts on a lab-scale ESR-plant. The investigated parameters included a variation of the slag compositions and the use of a protective nitrogen atmosphere. Variations of the slag composition comprised slags with different contents of CaF₂, CaO and Al₂O₃ as well as a variation of the SiO₂-content. The remelted ingots were forged and analyzed regarding their chemical composition as well as their distribution and composition of the non-metallic inclusions (NMI) by automated SEM-EDX method. The chemical composition of the slag after remelting was analyzed as well. The results clearly show a relationship mainly of Si and Al in the steel with the process parameters. NMI changed in their total amount, type and size distribution. The protective atmosphere reduced the Si-losses during remelting. The majority of the NMI were of the Al₂O₃- & MnS-type. In general, remelting lead to an almost complete removal of sulfides, a reduction of oxisulfides and a shift towards more oxides. The total amount of NMI was most strongly reduced by the high CaF₂-containing remelting slag.

Transverse cracking of continuously cast products has been encountered at almost every caster operation. Enormous efforts have been carried out in the past aiming at identifying the cause and reducing the problem, especially on steel grades with peritectic chemistries. So far, however, there is still no cost-effective solution with good trade-off for internal quality and productivity. In this study, a new cracking formation mechanism is proposed based on observations of equally spaced crack pattern and the undulation (shell thinning pattern) observed on the inside and/or outside (surface depression) of the breakout shell with similar spacing. This wavy solidification shell forms at initial solidification stage and induces the local shell thinning and reheating which in turn causes the local "Blown grains" inside the solidification shell. As observed on slab surfaces, these blown grains are closely related to transverse cracking problem.

The need for efficient and clean solutions, due to the increasing current environmental regulations puts extra pressure on new combustion engine development, to compete in a market with alternative driving concepts. Downsizing and weight reduction can reduce the engine emission and efficiency, but require light alloys with superior thermo-mechanical properties for high temperature exposure to maintain the same engine performance. Cast Al-Cu could be alternative to standard Al-Si alloys for new engine generations due to their higher temperature strength, creep-resistance and long term stability of engine components. In Al-Si and Al-Cu cast alloys with heterogeneous microstructures a composite-like deformation behavior is responsible for superior high temperature properties. Stiff Si or Al₂Cu particles, respectively reinforce a ductile α-Al matrix to a composite with improved thermo-mechanical strength. However, different Young's moduli and coefficients of thermal expansion are responsible for micro stress gradients and unpredictable micro crack formation under operation. These micro-mechanical deformation mechanisms in Al-Si and Al-Cu systems, responsible for crack initiation and growth, have been scarcely investigated so far.

This manuscript describes an example of elasto-plastic deformation mechanisms in an AlCu7 alloy. Tensile testing shows anomalous macroscopic deformation behavior indicating unknown internal micro-mechanical processes. External loading until yield strength and beyond are applied under laboratory conditions and during in-situ neutron diffraction. The results of macroscopic deformation and micro strain evolution are compared and correlated with the heterogeneous micro structure. High resolution synchrotron computed tomography reveals conclusions on the micro-mechanic deformation mechanisms and their effects on the macroscopic damage initiation and material's service performance.

In this study, the pores in die-cast AlSiMgMn alloys were inspected and reconstructed with high resolution three-dimensional (3D) X-ray micro computed tomograpgy (μ-CT) technique. Finite element (FE) meshes were built with consideration of the pore actural morphorloges from the CT inspection. Based on dutile damage model, the FE simulation of tensile fracture of the alloys was carried out. The simulation results were compared and verified with the tensile of in-situ scanning electron microscopy (SEM). The two results are agreement in the main crack path and pores on the fracture. With the pore-scale simulation, the effects of pore characteristics on the stress distributions and crack initiation and growth during the tensile were analyzed. It was found that the pores of lower sphericity and larger project area in tensile axis direction are prone to form microcracks and promote main crack deflection. The results also show that aggregation of brittle alpha-Fe intermetallics of the alloys also has important influence on the main crack propagation.

Cast components generally show a heterogeneous distribution of material properties, caused by variations in the microstructure that forms during solidification. Variations caused by the casting process are not commonly considered in structural analyses, which might result in manufacturing of sub-optimised components with unexpected in-use behaviour. In this paper, we present a methodology which can be used to consider both thermomechanical and thermophysical variations using finite element analyses in cast components. The methodology is based on process simulations including microstructure modelling and correlations between microstructural features and material properties. Local material data are generated from the process simulation results, which are integrated into subsequent structural analyses. In order to demonstrate the methodology, it is applied to a cast iron cylinder head. The heterogeneous distribution of material properties in this component is investigated using experimental methods, demonstrating local variations in both mechanical and physical behaviour. In addition, the strength-differential effect on tensile and compressive behaviour of cast iron is considered in the modelling. The integrated simulation methodology presented in this work is relevant to both design engineers, production engineers as well as material scientists, in order to study and better understand how local variations in microstructure might influence the performance and behaviour of cast components under in-use conditions.

The determination of pattern dimensions using simulation is an inefficient trial-and-error process that requires several design iterations. In this study, the finite element inverse elastoplastic analysis is utilized to calculate the pattern geometry in a single iteration for a plastically deformed body. A simplified casting system is simulated to demonstrate the feasibility of the inverse method. An inverse simulation is performed first to calculate the pattern shape. This configuration is then used as the input geometry for a forward simulation, which is shown to successfully recover the original as-cast shape used for the inverse analysis. Through this sequence, the inverse deformation method is shown to be a viable technique for the determination of pattern allowances in production castings.

Tailored heterogeneous distributions of microstructural features enable extraordinary material performance in biological and physiological structures such as trees, the aortic arch, human teeth and dinosaur skulls. In ductile iron, a heterogeneous distribution in size and morphology of graphite nodules and variations of the fractions of ferrite and pearlite are created during solidification, and varies as a function of parameters such as local cooling rate, segregation and flow. In the current work, the size distribution as well as the orientation and relation between graphite nodules is obtained by a three-dimensional reconstruction of a ductile iron microstructure from X-ray tomography. The effect of the nodule morphology and clustering on the localization of plastic strains is studied numerically using finite element analysis of the reconstructed microstructure. Real castings have a variation in geometry, solidification conditions and are subjected to variations in loads. A framework for optimized geometry and solidification conditions in order to design and deliver castings with tailored local material performance is proposed.

The foundry engineering still needs new cast materials of improved properties. These can be achieved by elaborating completely new alloys and metal matrix composites or by elaborating the alloys/composites basing on the already very well-known matrixes. The good example of the latter solution are high-aluminium zinc (H-Al Zn) and high-zinc aluminium cast alloys (H-Zn Al). Both of these groups show good damping and strength properties but rather low ductility and insufficient structural (and dimensional) stability, caused by long term transformation of the Cu-containing bearing phases. The performed works were devoted, among others, to building composites of improved structural stability reinforced with ternary (Al, Zn)-Ti aluminides. The in-situ reinforcement was built by needle-shape ternary aluminides based on the DO₂₂ TiAl₃ binary phase introduced with AlTi-based master alloys or by compacted semi-globular ones based on the L1₂ Zn₃Ti particles introduced with a ZnTi-based master alloy. The mentioned particles substitute partly or totally for Cu-based bearing phase and the influence of this substitution on the structural stability and tribological properties is also discussed in the paper.

In recent years, the automotive industry has been increasing the production of small, high-power gas engines as part of several strategies to achieve the new "Corporate Average Fuel Economy" (CAFE) standards. This trend requires an improvement in the thermal and mechanical fatigue durability of the aluminium alloys used in the production of the cylinder blocks in these engines. Conventionally, solid chills are employed in areas of these castings subject to high cyclic loading to enhance the mechanical performance of the cast material – i.e. in the main bearing bulkhead. A potential means of improving the efficacy of these chills is to incorporate water cooling. To assess the effectiveness of this method, a water-cooled chill was designed and installed in a bonded-sand engine block mould package (1/4 section). The moulds were instrumented with thermocouples, to measure the evolution of temperature at key locations in the casting, and "Linear Variable Displacement Transducers" (LVDTs), to measure the gap formation at the interface between the chill and the casting. This paper summarizes, at a high level, some of the findings of this work.

As it is known from literature, the metals tend to follow a viscoplastic law at high temperatures. Thereby, based on the authors' previous developments to simulate the behavior of the equiaxed crystals packed bed, a viscoplastic stress model is applied to the thin slab casting process. The model is reduced to the single phase mixture formulation for faster and robust simulations. In this idea, the solidifying shell represents a 'creeping solid' and the Norton-Hoff type stress model is formulated with the model parameters obtained experimentally. A coupling procedure is established to converge the non-linear terms. The influence of the stress model parameters is investigated. Next the model is applied for the simulation of the thin slab casting to improve a previously developed technique: a viscoplastic rheology is applied to calculate the motion of the solidifying melt instead of imposing the velocities of the mush. The simulation results show that the most deformations happen at the funnel part of the mold, causing highest strain rates and the significant drop of the viscoplastic 'apparent viscosity' according to the Norton-Hoff law. The solid shell velocities are mostly uniform at the straight parts of the strand but a slight acceleration of the shell is observed along the funnel surface. Strong compression / expansion zones are detected at the funnel part, which could lead to defects formation. The solid shell thickness was successfully predicted as well and compared to the previous work by the authors.

Continuous casting is currently the main industrial process for steel production. Since long time, industries search for efficient simulation methods, by which macrosegregation and deformation induced cracks can be predicted. As a first step this requires achieving concurrent simulation of fluid flow and stress-strain. Therefore, a partitioned solution algorithm is developed for such simulation with application to continuous casting. Liquid flow induced by natural convection or filling step, solidification shrinkage as well as thermally induced deformation of solid phase are accounted for.

To describe the thermomechanical behaviour of the semi-solid state during alloy solidification, specific viscoplastic constitutive laws are derived for the coherent and non-coherent regime of the mush. For the coherent semi-solid regime an original viscoplastic flow potential is derived, which includes micro-structural parameters. This potential takes also isotropic hardening, pressure dependence of yielding and the strength difference in tension and compression into account. For the non-coherent mushy state of suspensions under shear loading, a simplified viscoplastic potential is adopted by neglecting pressure effects on the solid dendrites. Continuity at mechanical coherency is imposed and allows the reduction of the model parameters of the non-coherent regime. The developed constitutive laws are implemented in Abaqus via a user-defined CREEP routine. Simulations of uniaxial tension, compression or pure shear experiments allow identifying the model parameters of an A356 aluminium alloy.

The grain boundary groove method has been successfully used to measure solid-liquid interfacial energies, σ_SL, experimentally for binary eutectic and peritectic systems, multi-component systems as well as pure materials and for opaque materials as well as transparent materials. It was shown that the grain boundary groove method can be use to obtain σ_SL for any alloy system provided that the prepared alloy sample can be held at the evaluated temperature for a long enough time with a very stable temperature gradient. In order to show the applicability of the groove method to any system, a part of the Al-Zn phase diagram was chosen. Equilibrated grain boundary groove shapes for solid Alα solution (Al-30wt%Zn) in equilibrium with AlZn liquid (Al-60wt%Zn) have been directly observed with a radial heat flow apparatus. The Gibbs-Thomson coefficient, Γ, was determined with a numerical method using observed groove shapes. The measured thermal conductivities of the solid Alα solution and AlZn liquid phases and the temperature gradient in the solid phase at the solid-liquid interface were used for the calculation of Γ and then σ_SL was determined using the Gibbs-Thomson equation. The grain boundary energy for the same system was also obtained from the observed groove shapes. The results of the work were compared with the results of the related experimental works.