BY:

ADMI SSI ON. EDHOLE. COM

MCA Admission in India
NTNU
Short Course on solidification at IISc October November
2012
Lars Arnberg, NTNU
2
1. Introduction basic concepts 29/10

1. Nucleation - grain refinement 31/10
Crystal morphology

3. Interface stability 5/11
Cells and dendrites

4. Three phase solidification 7/11
Segregation

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Solidification, Lecture 1
3
Introduction / Basic concepts
Simple heat flow during solidification
Mushy Zone
Columnar / equiaxed solidification
Curvature effects
Phase diagrams solute redistribution


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Microstructure
4
Solidification of metals is a crystallisation process


Microstructure development

Microstructure

Crystal types, phases
Crystal morphology
Crystal size
Chemical composition
Depends on

Composition (constitution)
Concentration, C
Phase diagram, k, m
Casting conditions
Growth rate, V
Temperature gradient, G
Cooling rate, G*V
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Microstructure
5
Increasing concentration

Increasing constitutional
undercooling (T
c
)

Increasing morphological
instability
Increasing cooling rate (G*V)

Structure refinement
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Heat flow
6
Reproduced from:W. Kurz & D. J. Fisher:
Fundamentals of Solidification
Trans Tech Publications, 1998

q
A
v
c
dT
dt
H
df
s
dt

dT
dt
q
A
vc

df
s
dt
H
c
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Mushy zone
7
a
Alloys will solidify over a
temperature Interval, T
f


M. Z. is where solidification
occurs

Depending on freezing
range and temp gradient

a
T
f
G
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Controlled solidification
8
a: Bridgman furnace
Independent control of G & V.
G & V constant

b: Directional chill casting
G & V time dependant

dT/dt = GV

s=Kt
1/2

Reproduced from:W. Kurz & D. J. Fisher:
Fundamentals of Solidification
Trans Tech Publications, 1998
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Growth modes
morphology & temperature distribution
9
Directional
Growth of
columnar
crystals
Free growth
of equiaxed
crystals
Positive G Negative G
Pure metal
Alloy
Reproduced from:W. Kurz & D. J. Fisher:
Fundamentals of Solidification
Trans Tech Publications, 1998
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10
Structure of castings
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Capillary effects; solid/liquid interface
Undercooling


Curvature
2/r for sphere


Gibbs Thomson
~ 10
-7
Km


dA
K
dV
=
11
Solidification microstructures
given by competition between:

Curvature : tends to maximise scale

Diffusion: tends to minimise scale
Reproduced from:W. Kurz & D. J. Fisher:
Fundamentals of Solidification
Trans Tech Publications, 1998

T K



s
f
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Phase digram, solute redistribution
12
C
s

C
0

T
0

C
0

l
s
T
C
l

T
l

T
s

Eutectic phase diagram

Lower solubility
of alloying elements
in s than in l

k=C
s
/C
l
<1 (distribution
coefficient)

m= dT
l
/dC<0

k and m constants if solidus
& liquidus lines are straight


C

T
0
mC
0
m
C
0
(1k)
k
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13
Al-Fe Al-Mg
Al-Mn
Al-Si
Eutectic Al
phase diagrams
for important
alloying
elements
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14
Al-Fe
k=0.03
AlMg
k=0.44
Al-Mn
k=0.90
Al-Si
k=0.14
Al phase
diagrams with
different
partition
coefficients

k=C
s
/C
l

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Summary/ Conclusions
15
Solidification is accomplished by external cooling of a melt. Needed for
decreasing the temperature and removing latent heat of fusion
Metals solidify at a distinct freezing point, alloys have a solidification
interval (freezing range)
Solidification microstructure will depend on both composition, (C
0
)
constitution (k, m) and process (G, V)
Control of V and G will differ between casting processes
Solidification will occur in mushy zone. Extent of MZ will depend on
temperature gradient and freezing range
Crystal may grow directionally as columnar grains (G>0) or freely from
an undercooled melt as equiaxed grains (G<0)
Creation of s/l interface will require undercooling. T
r
will increase
with increased curvature (small crystal radii)


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Summary/ Conclusions
16
Scale of solidification microstructure will be determined by diffusion
(decreasing) and curvature (increasing)
Solidification of alloys means redistribution of solute between s and l.
Determined by distribution coefficient, k.
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Symbols
17
C: concentration G: temperature gradient, dT/dx K/m
k: distribution coefficient k=C
s
/C
l
s
f
: entropy of fusion, J/(m
3
K)

m: liquidus slope, dT/dC : solid/liquid interface energy, J/m
2

V: growth rate m/s C
l
: liquid concentration
T: temperature: K C
s
: solid concentration
T: undercooling, K C
0
: Initial alloy concentration
q: heat flux W/m
2

A: area m
2
V: volume m
3

t: time, s
H: heat of fusion J/m
3

c: heat capacity: J/(m
3
K)
f
s
: fraction solid
T
f
: freezing range, K

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