Numerical simulation of channel segregates during alloy solidification using TVD schemes

This paper aims to tackle the problem of thermo‐solutal convection and macrosegregation during ingot solidification of metal alloys. Complex flow structures associated with the development of channels segregate and sharp gradients in the solutal field call for the implementation of accurate methods for numerical modeling of alloy solidification. In particular, the solute transport equation is convection dominated and requires special non‐oscillarity type high‐order schemes to handle the regions of channels segregates.

In the present study, a time‐splitting approach has been adopted to separately handle solute advection and diffusion. This splitting technique allows the application of accurate total variation dimensioning (TVD) schemes for solution of solute advection. Applications of second‐order Lax‐Wendroff TVD SUPERBEE and fifth‐order weighted essentially non‐oscillatory (WENO) schemes are described in the present article. Classical numerical solution of solute transport using hybrid and central‐difference schemes are also employed for the purpose of comparisons. Numerical simulations for solidification of Pb‐18%Sn in a two‐dimensional rectangular cavity have been carried out using different numerical schemes.

Numerical results show the difficulty of obtaining grid‐independent solutions with respect to local details in the region of channels. Grid convergence patterns and numerical uncertainty are found to be dependent on the applied scheme. In general, the first‐order hybrid scheme is diffusive and under predicts the formation of channels. The second‐order central‐difference scheme brings about oscillations with possible non‐physical extremes of solute composition in the region of channel segregates due to sharp gradients in the solutal field. The results obtained using TVD and WENO schemes contain no oscillations and show an excellent capture of channels formation and resolution of the interface between solute‐rich and depleted bands. Different stages of channels formation are followed by analyzing thermo‐solutal convection and macrosegregation at different times during solidification.

Accurate prediction of local variation in the solutal and flow fields in the channels regions requires grid refinement up to scales in the order of microscopic dendrite arm spacing. This imposes limitations in terms of large computational time and applicability of available macroscopic models based on classical volume‐averaging techniques.

The present study is very useful for numerical simulation of macrosegregation during ingot casting of metal alloys.

The paper provides the methodology and application of TVD schemes to predict channel segregates during columnar solidification of metal alloys. It also demonstrates the limitations of classical schemes for simulation of alloy solidification.