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Open AccessArticle

Mushy Zone Morphology Calculation with Application of CALPHAD Technique

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
Institut für Werkstoff-Forschung, German Aerospace Center DLR, Linder Höhe, 51147 Köln, Germany
Author to whom correspondence should be addressed.
Metals 2017, 7(9), 363;
Received: 20 July 2017 / Revised: 5 September 2017 / Accepted: 5 September 2017 / Published: 12 September 2017
Mushy zone morphology in AlSiMn alloys was studied using directional solidification, and the CALPHAD (Computer Coupling of Phase Diagrams and Thermochemistry) technique was applied for thermodynamic calculations. The specimens solidified with forced convection presented segregation across the sample diameter, and the measured compositions were located on the Al-Si-Mn phase diagram. Scheil-Gulliver calculations for measured compositions were used to determine various solidification paths that may occur in specimens. Property diagrams and solidification paths presented the segregation effect on the characteristic temperatures, mushy zone length and the sequence of occurring phases whilst 2D maps enabled visualization of the mushy zone during directional solidification. Melt stirring was found to change solidification range, as well as mushy zone length and shape, and the dendrite tips formed a rough profile across the specimens. The study revealed mushy zones with dense dendritic structure and liquid channels empty of Mn phases, where intermetallics had no possibility to flow in the liquid, whilst in other samples with channels filled with Al15Si2Mn4, Mn-precipitates also flowed above the α-Al. The melt flow may lead to a mainly dendritic mushy zone or to a mushy zone with dendrites reaching only lower half of mushy length with intermetallics forming and freely flowing above dendrites in the liquid upper half. View Full-Text
Keywords: aluminum alloys; mushy zone; directional solidification; CALPHAD; Mn intermetallics; Al15Si2Mn4 aluminum alloys; mushy zone; directional solidification; CALPHAD; Mn intermetallics; Al15Si2Mn4
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Mikolajczak, P.; Genau, A.; Ratke, L. Mushy Zone Morphology Calculation with Application of CALPHAD Technique. Metals 2017, 7, 363.

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