• Transactions of the Korean Society of Mechanical Engineers B
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• v.33 no.7
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• pp.469-476
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• 2009

Most material of engineering interest undergoes solidification process from liquid state. Identifying the underlying mechanism during solidification process is essential to determine the microstructure of material thus the physical properties of final product. In this paper, effect of fluid convection on the dendrite solidification morphology is studied using Level Contour Reconstruction Method. Sharp interface technique is used to implement correct boundary condition for moving solid interface. The results showed good agreement with exact boundary integral solution and compared well with other numerical techniques. Effects of Peclet number and undercooling on growth of dendrite tip of both single and multiple seeds have been also investigated.

• Proceedings of the KSME Conference
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• 2000.04b
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• pp.37-44
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• 2000

Numerical investigation is made to study the effects of natural convection on the formation of macrosegregation of a Pb-Sn alloy solidification process in a 2-D confined rectangle mold. The governing equations are calculated using previous continuum models with SIMPLE algorithm doring the solidification process. In addition. to track the solid-liquid interface with time variations. the moving boundary condition Is adopted and irregular interface shapes are treated with Boundary-Fitted Coordinate system. As the temperature reduce from the liquidus to the solidus, the liquid concentration of Sn. the lighter constituent, increases. Then the buoyancy-driven flow due to temperature and liquid composition gradients, called thermosolutal convection or double diffusion, occurs in the mushy region and forms the complicated macrosegregation maps. Related to this phnomena, effects on the macrosegregation formation depending on the cooling condition and gravity values are described.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.25 no.10
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• pp.1337-1345
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• 2001

Numerical investigation is made to study the effects of thermosolutal convection on the formation of macrosegregation in a Pb-Sn alloy solidification process in a two dimensional confined rectangluar mold. The basic equations are sovled using the Contrinum Model theory with the SIMPE algorithm during the solidification process. In addition, to track the liquid-solid interface with time variations, the moving boundary condition was adopted and moving irregular interface shapes were treated with the time-dependent, boundary-fitted coordinate system. As the temperature reduces from the liquidus to the solidus, the liquid concentration of Sn, the lighter constituent, increases. Then the buoyancy-driven flow due to temperature and liquid composition gradients occurs in the mushy region and forms the complicated macrosegregation maps. belated to this phenomena, effects on the macrosegregation formation depending on the cooling condition and gravity values are examined.

• Journal of computational fluids engineering
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• v.6 no.1
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• pp.1-13
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• 2001

The natural convection heat transfer and solidification in a stratified pool are studied. The flow and heat transfer characteristics in a heat generating pool are compared between single-layered and double-layered pools. And local Nusselt number distributions on outer walls are obtained to consider thermal loads on a vessel wall. The cooling and solidification of Al₂O₃/Fe melt in a hemispherical vessel are simulated to study the mechanism of heat transfer and temperature distribution. A unstructured mesh is chosen for this study because of the non-orthogonality originated from the boundaries of double-layered pool. Interface between the layers is modeled to be fixed. With this assumption mass flux across the interface is neglected, but shear force and heat flux are considered by boundary conditions. The colocated cell-centered finite volume method is used with the Rhie-Chow interpolation to compute cell face velocity. To prevent non-physical solutions near walls in case body force is large the wall pressure is extrapolated by the way to include body force. The numerical solutions calculated by current method show that averaged downward heat flux of the double-layered pool increases compared to single-layered pool and maximum temperature occurs right below the interface of the layers.

• Coupled systems mechanics
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• v.5 no.4
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• pp.341-353
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• 2016

Manufactures of multi-crystalline silicon ingots by means of the directional solidification system (DSS) is important to the solar photovoltaic (PV) cell industry. The quality of the ingots, including the grain size and morphology, is highly related to the shape of the crystal-melt interface during the crystal growth process. We performed numerical simulations to analyze the thermo-fluid field and the shape of the crystal-melt interface both for steady conditions and transient processes. The steady simulations are first validated and then applied to improve the hot zone design in the furnace. The numerical results reveal that, an additional guiding plate weakens the strength of vortex and improves the desired profile of the crystal-melt interface. Based on the steady solutions at an early stage, detailed transient processes of crystal growth can be simulated. Accuracy of the results is supported by comparing the evolutions of crystal heights with the experimental measurements. The excellent agreements demonstrate the applicability of the present numerical methods in simulating a practical and complex system of directional solidification system.

• Korean Journal of Metals and Materials
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• v.50 no.12
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• pp.897-905
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• 2012

Directional solidification experiments were carried out in a hypoeutectic Al-11.3Si-3.5Cu system to investigate the microstructural evolution with the solidification rate. At a fixed temperature gradient, a dendritic microstructure was observed at a constant speed of more than $25{\mu}ms^{-1}$, a cellular interface developed at $5{\mu}ms^{-1}$ and the growth rate of $0.5{\mu}ms^{-1}$ led to the stability of the planar interface. The results revealed that primary silicon phases formed among cells, even though the studied Al-Si alloy system formed the composition within a hypoeutectic silicon composition. This suggests that the liquid concentration among cells during solidification reached a higher concentration, i.e., the eutectic concentration. It is, however, interesting that primary silicon phases did not form during a dendritic growth of more than $25{\mu}ms^{-1}$. These experimental observations are explained using the theoretical models on the interface temperatures.

• Korean Journal of Materials Research
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• v.18 no.11
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• pp.577-582
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• 2008

Directional solidification experiments were carried out at $1-300\;{\mu}m/sec$ solidification rates in the single crystal superalloy, CMSX 10. The solid/liquid interface morphology changed from planar to dendritic, and the dendrite spacing became finer as the solidification rate increased. The pool size of the ${\gamma}/{\gamma}'$ eutectic, formed between dendrites, reduced as the solidification rate increased. The phase formation temperatures, such as the solidus, liquidus and eutectic, were estimated by differential scanning calorimetry (DSC) analysis. The morphology of the ${\gamma}/{\gamma}'$ phase, known to be eutectic, showed ${\gamma}'$ cells with a $\gamma$ intercellular network, and this ${\gamma}/{\gamma}'$ was composed of coarse and fine ${\gamma}/{\gamma}'$ regions. In this study, it is suggested that the ${\gamma}/{\gamma}'$ phase was a coupled peritectic.The solidification procedure of the ${\gamma}/{\gamma}'$ between dendrites is also discussed.

• Korean Journal of Metals and Materials
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• v.47 no.7
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• pp.440-446
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• 2009

Co base superalloys have been widely used for the parts of gas turbine due to their excellent strength, thermal fatigue, oxidation resistance and weldability at high temperature. In this study, directional solidifications were carried out at various solidification rates, including $0.5{\sim}300{\mu}m/s$ in the Co base superalloy FSX-414. The cellular interface were formed at a low solidification rate, $1{\mu}m/s$, and the dendritic interface was found at higher solidification rates, $5{\sim}300{\mu}m/s$. As the spacing of dendrite structure decreased, the size and spacing of eutectics decreased. Dendrite arm spacing decreased with increasing solidification rates and temperature gradient. It was interesting to find the $M_{23}C_{6}$ eutectic microstructure formed between $\gamma$ dendrites. Composition analysis showed that Cr and W were segregated severely between the dendrites, which resulted in the formation of Cr-rich $M_{23}C_{6}$ and W-rich MC carbides.

• Korean Journal of Air-Conditioning and Refrigeration Engineering
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• v.10 no.3
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• pp.260-270
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• 1998

The viscous plane stagnation-flow solidification problem is theoretically investigated. An analytic solution at the beginning of solidification is obtained by expanding the temperature and thickness of solidified layer in powers of time. An exact expression for the steady-state thickness of solidified layer is also obtained. The .fluid flow toward the cold substrate inhibits the solidification process. As Stefan number becomes larger, or Prandtl number becomes smaller, the solidification is more strongly inhibited by the fluid flow. The transient heat flux at the liquid side of solid-liquid interface is increased, as Stefan number or Prandtl number is increased.

• Korean Journal of Materials Research
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• v.12 no.12
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• pp.897-903
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• 2002

Morphological evolution and growth mechanism at the solid/liquid interface during solidification were investigated in the Ni-base superalloy GTD111M by directional soldification and quenching(DSQ) technique. The experiments were conducted by changing solidification rate(V) and thermal gradient(G) which are major solidification process variables. High thermal gradient condition could be obtained by increasing the furnace temperature and closely attaching the heating and cooling zones in the Bridgeman type furnace. The dendritic/equiaxed transition was found in the G/V value lower than $0.05$\times$10{^3}^{\circ}C$s/$\textrm{mm}^2$, and the planar interface of the MC-${\gamma}$ eutectic was found under $17 $\times$ 10{^3}^{\circ}C$ s/$\textrm{mm}^2$. It was confirmed that the dendrite spacing depended on the cooling rate(GV), and the primary spacing was affected by the thermal gradient more than solidification rate. The dendrite lengths were decreased as increasing the thermal graditne, and the dendrite tip temperature was close to the liquidus temperature at $50 \mu\textrm{m}$/s.