Volume-Averaged Modeling of Multiphase Flow Phenomena during Alloy Solidification

• Main Authors: Menghuai Wu, Andreas Ludwig, Abdellah Kharicha
• Format: Article
• Language: English
• Published: MDPI AG 2019-02-01
• Series: Metals
• Subjects: solidification; modeling; volume-averaged; macrosegregation; casting
• Online Access: https://www.mdpi.com/2075-4701/9/2/229

The most recent developments and applications in volume-averaged modeling of solidification processes have been reviewed. Since the last reviews of this topic by Beckermann and co-workers [Applied Mech. Rev. 1993, p. 1; Annual Rev. Heat Transfer 1995, p. 115], major progress in this area has included (i) the development of a mixed columnar-equiaxed solidification model; (ii) further consideration of moving crystals and crystal dendritic morphology; and (iii) the model applications to analyze the formation mechanisms of macrosegregation, as-cast structure, shrinkage cavity and porosity in different casting processes. The capacity of computer hardware is still a limiting factor. However, many calculation examples, as verified by the laboratory casting experiments, or even by the casting processes at a small industrial scale, show great application potential. Following the trend of developments in computer hardware (projection according to Moore’s law), a full 3D calculation of casting at the industry scale with the multiphase volume-averaged solidification models will become practically feasible in the foreseeable future.