The Coupling of Macrosegregation with Grain Nucleation, Growth and Motion in DC Cast Aluminum Alloy Ingots

The phenomena responsible for the formation of macrosegregations, and grain structures during solidification are closely intertwined. We present a model study of the formation of macrosegregation and grain structure in an industrial sized (350 mm thick) direct chill (DC) cast aluminum alloy slab. The modeling of these phenomena in DC casting is a challenging problem mainly due to the size of the products, the variety of the phenomena to be accounted for, and the non-linearities involved. We used a volume-averaged multiscale model that describes nucleation on grain refiner particles and grain growth, coupled with macroscopic transport: fluid flow driven by natural convection and shrinkage, transport of free-floating globular equiaxed grains, heat transfer, and solute transport. We analyze the heat and mass transfer in the slurry moving-grain zone that is a result of the coupling of the fluid flow and of the grain nucleation, growth and motion. We discuss the impact of the flow structure in the slurry zone and of the grain packing fraction on the macrosegregation.