Olga Budenkova

The development of a microgravity experiment involving columnar to equiaxed transition for solidification of a Ti-Al based alloy

The authors are members of the integrated project Intermetallic Materials Processing in Relation to Earth and Space Solidification (IMPRESS), funded within the European Framework (FP6). One of the aims of IMPRESS is to develop new alloys and processes for the casting of TiAl-based turbine blades for the next generation of aero and industrial gas turbine engines. Within IMPRESS, two related issues have been identified during the primary solidification stage, namely, segregation and the columnar-to-equiaxed transition (CET). The authors have set out to isolate the effects of thermo-solutal convection, by designing a microgravity experiment to be performed on a European Space Agency platform. This experiment will investigate the CET formation during solidification. It is planned to use a sounding rocket providing a microgravity time of approximately twelve minutes. The results of this microgravity solidification experiment will be used as unique benchmark data for development and validation of new computational models of TiAl solidification. This in turn will produce accurate models and ultimately new robust industrial processes by project partners in the aerospace industry. The evolution of the design of the microgravity experiment is discussed and the results of preliminary ground reference experiments are presented. Future plans and objectives for the project are also highlighted.

Comparison of Two Models for Simulation of Binary Alloy Solidification

The results of running a quasi two-dimensional experimental benchmark for horizontal directional solidification of binary Sn-3 wt.%Pb alloy in a rectangular region are presented. The computation was performed using the GIGAN software and two models to simulate the mushy zone were compared, namely, the one based on the equilibrium approach and the non-equilibrium one.

REVIEW OF THE MAXUS 8 SOUNDING ROCKET EXPERIMENT TO INVESTIGATE SOLIDIFICATION IN A TI-AL-NB ALLOY

Proceedings of the 20th European Space Agency Symposium on European Rocket and Balloon Programmes and Related Research (Hyeres, Provence, France, 22-26 May 2011)

Modeling of the effect of a thermoelectric magnetic force onto conducting particles immersed in the liquid metal

Simulation of a thermo-electromagnetic force which acts on a conducting particle immersed into liquid metal is performed using multi-gird multi-physics software AEQUATIO. To verify numerical solutions a model thermoelectric problem is solved using two methods. In the first one a phase function is used to indicate the phase transition whereas in the second the solid particle is described with a real frontier of a simplified shape. Numerical and analytical solutions for a model problem qualitatively agree but strong oscillations are observed in a numerical solution with a phase function. Further AEQUQTIO is applied for calculation of the velocity of a dendrite fragment observed in-situ in experiment of solidification of AlCu alloy. Numerical solution gives a good agreement with the experimental observation.

Formation of intermetallic phases in AlSi7Fe1 alloy processed under microgravity and forced fluid flow conditions and their influence on the permeability

Ternary Al-6.5wt.%Si-0.93wt.%Fe alloy samples were directionally solidified on-board of the International Space Station ISS in the ESA payload Materials Science Laboratory (MSL) equipped with Low Gradient Furnace (LGF) under both purely diffusive and stimulated convective conditions induced by a rotating magnetic field. Using different analysis techniques the shape and distribution of the intermetallic phase β-Al5SiFe in the dendritic microstructure was investigated, to study the influence of solidification velocity and fluid flow on the size and spatial arrangement of intermetallics. Deep etching as well as 3-dimensional computer tomography measurements characterized the size and the shape of β-Al5SiFe platelets: Diffusive growth results in a rather homogeneous distribution of intermetallic phases, whereas forced flow promotes an increase in the amount and the size of β-Al5SiFe platelets in the centre region of the samples. The β-Al5SiFe intermetallics can form not only simple platelets, but also be curved, branched, crossed, interacting with dendrites and porosity located. This leads to formation of large and complex groups of Fe-rich intermetallics, which reduce the melt flow between dendrites leading to lower permeability of the mushy zone and might significantly decrease feeding ability in castings.

Modelling of Al-7%wtSi-1wt%Fe Ternary Alloy: Application to Space Experiments with a Rotating Magnetic Field

Recently several experiments on directional solidification of Al-6.5wt.Si-0.93wt.%Fe (AlSi7Fe1) alloy were performed under terrestrial conditions and onboard the International Space Station (ISS) in the Materials Science Lab (MSL) with use of electromagnetic stirring and without it. Analysis of the samples showed that stirring with a rotating magnetic field lead to the accumulation of iron-rich intermetallics in the center of the sample and influenced the primary dendrite spacing while the secondary dendrite arm spacing were not affected. In the present paper the accumulation of the intermetallics b-Al5SiFe in the center of the samples due to RMF stirring is demonstrated numerically and the evolution of primary and secondary dendrite arm spacing is discussed.

In Situ and Real-Time Analysis of TEM Forces Induced by a Permanent Magnetic Field during Solidification of Al-4wt%Cu

It is well known that the application of a magnetic field during the growth process can have pronounced effects on cast material structures and their properties, so that magnetic fields have been widely applied since the 1950s. In the case of a permanent magnetic field, some recent results revealed a dual effect on the liquid metal flow. 1: the magnetic field has a selective damping action on the flow at the scale of the crucible, due to the Lorentz force; 2: the interaction of thermo-electro-magnetic (TEM) currents in the close vicinity of the solid-liquid interface with the applied magnetic field leads to the generation of electromagnetic forces, which act both on the liquid and on the solid at the scale of the microstructure. We present an experimental investigation of the TEM forces induced by a permanent magnetic field during columnar and equiaxed solidification of Al-4wt%Cu. In situ visualization was carried out by means of synchrotron X-ray radiography, which is a method of choice for studying dynamic phenomena. It was shown that the TEM forces were at the origin of a motion of dendritic particles, perpendicular to the direction of gravity. A heuristic analysis allowed us to estimate the fluid velocities and the velocities of the solid particles, and a good agreement was achieved with the experimental data. Similar observations were also made during equiaxed growth in a temperature gradient. The in situ observation of the grain trajectories for various values of the temperature gradient demonstrated that gravity and TEM forces were the driving forces which controlled the grain motion.

Numerical Simulation of the RMF Stirring of Molten Ga-In Alloy Using RANS K-ε and LES Turbulence Models

A comparison of the results of RANS k-ε and LES turbulence models was done via the simulation of the electromagnetic stirring of liquid 75,5%Ga-24,5%In alloy (in a 10 mm diameter & 30 mm high crucible) using Ansys Fluent. Each velocity component, the distribution of eddies inside the melt and other flow parameters were compared respectively. The accuracy was checked with measured angular velocity data of A. Rónaföldi. The turbulent energy spectra were also produced to see the validity of the LES models.

Comparison between Simulation and Experimental Results of the Effect of RMF on Directional Solidification of Al-7wt.%Si Alloy

A numerical investigation of directional solidification of Al-7wt.%Si alloy stirred by a rotating magnetic field is compared with experimental results. Experimental study of such process has revealed periodical macrosegregation in axial direction of the samples in the shape of a “Christmas tree”. Similar macrosegregation pattern is obtained in simulations for the two values of magnetic field. Numerical simulations have shown also that formation of the periodical structure depends not only on the external conditions but on the permeability of the mushy zone.