Three-dimensional simulation of the influence of convection on dendritic solidification

Bulk and interdendritic flow during solidification alters the microstructure development, potentially leading to the formation of defects. In this paper, a 3D numerical model is presented for the simulation of dendritic growth in the presence of fluid flow in both liquid and semi-solid zones during solidification. The dendritic growth was solved by the combination of a stochastic nucleation approach with a finite difference solution of the solute diffusion equation and. a projection method solution of the Navier-Stokes equations. The technique was applied first to simulate the growth of a single dendrite in 2D and 3D in an isothermal environment with forced fluid flow. Significant differences were found in the evolution of dendritic morphology when comparing the 2D and 3D results. In 3D the upstream arm has a faster growth velocity due to easier flow around the perpendicular arms. This also promotes secondary arm formation on the upstream arm. The effect of fluid flow on columnar dendritic growth and micro-segregation in constrained solidification conditions is then simulated. For constrained growth, 2D simulations lead to even greater inaccuracies as compared to 3D.

Thermoelectric MHD in dendritic solidification

The effects of a constant uniform magnetic field on dendritic solidification were investigated using an enthalpy based numerical model. The interaction between thermoelectric currents on a growing crystal and the magnetic field generates a Lorentz force that creates flow. The need for very high resolution at the liquid-solid boundary where the thermoelectric source originates plus the need to accommodate multiple grains for a realistic simulation, make this a very demanding computational problem. For practical simulations, a quasi 3-dimensional approximation is proposed which nevertheless retains essential elements of transport in the third dimension. A magnetic field normal to the plane of growth leads to general flow circulation around an equiaxed dendrite, with secondary recirculations between the arms. The heat/solute advection by the flow is shown to cause a change in the morphology of the dendrite; secondary growth is promoted preferentially on one side of the dendrite arm and the tip velocity of the primary arm is increased. The degree of approximation introduced is quantified by extending the model into 3-dimensions, where the full Navier-Stokes equation is solved, and compared against the 2-dimensional solution.