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Metals 2017, 7(11), 506;

Thermo-Calc Prediction of Mushy Zone in AlSiFeMn Alloys

Institute of Materials Technology, Poznan University of Technology, Piotrowo 3, 60-965 Poznan, Poland
Department of Materials Science and Engineering, University of Alabama at Birmingham, 1720 2nd Avenue South, Birmingham, AL 35294, USA
Institute of Electrical Power Engineering, Poznan University of Technology, Piotrow 3A, 60-965 Poznan, Poland
Institut fürWerkstoff-Forschung, German Aerospace Center DLR, Linder Höhe, 51147 Köln, Germany
Author to whom correspondence should be addressed.
Received: 22 October 2017 / Revised: 10 November 2017 / Accepted: 13 November 2017 / Published: 16 November 2017
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Convection forces can cause significant segregation within the liquid during directional solidification, influencing the structure of the mushy zone and the type and distribution of phases present in the solidified alloy. The solidification behavior of AlSiFeMn alloys with strong convection was investigated via experimental results combined with thermodynamic calculations. Experimental specimens were processed in a directional solidification facility with forced melt flow, resulting in high levels of elemental segregation across samples. The resulting local compositions were located on phase diagrams Al-Si-Fe, Al-Si-Mn and Al-Fe-Mn for prediction of the variation in solidification behavior. Phase mass fraction diagrams created in Thermo-Calc showed the effect of segregation on the characteristic temperatures, mushy zone length and the order of occurring phases precipitating across specimens. These findings were used to create 2D maps for visualization of the mushy zone, mass fraction of α-Al dendrites, β-Al5FeSi, Al15Si2Mn4 and their spatial location. The specimen centers showed enrichment in AlSi-eutectic but for β-Al5FeSi and Al15Si2Mn4 results are ambiguous. Fe-phases start to grow mainly behind the dendrites tips and in general may flow between them. Mn-rich phases start to precipitate at higher temperatures than β and in many places before α-Al and in this way may flow in the melt above the mushy zone. View Full-Text
Keywords: mushy zone; aluminum alloys; directional solidification; Thermo-Calc; Fe- Mn- intermetallics; β-Al5FeSi; Al15Si2Mn4 mushy zone; aluminum alloys; directional solidification; Thermo-Calc; Fe- Mn- intermetallics; β-Al5FeSi; Al15Si2Mn4

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Mikolajczak, P.; Genau, A.; Janiszewski, J.; Ratke, L. Thermo-Calc Prediction of Mushy Zone in AlSiFeMn Alloys. Metals 2017, 7, 506.

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