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• W1959289018 abstract "Manufacturing of light-weight materials is associated with several types of casting defects during solidification. Porosity defects are common, especially in aluminum and its alloys, which initiate crack propagation and thereby cause drastic deterioration in the mechanical properties. These defects, classified as micro and macro defects (based on their sizes), are mainly governed by release of hydrogen into the liquid at the solid-liquid interface, which triggers the nucleation and growth of hydrogen bubbles in the melt. Subsequently, these bubbles interact with solidifying interfaces such as dendritic arms and eutectic fronts, leading to the formation of pores. Macroscopic defects in the form of voids are created due to solidification shrinkage. The primary focus of the present work is to develop phenomenological models for the evolution of microporosity and microstructures during solidification. The issues outlined above typically occur in multi-phase environments comprising of solid, liquid and gaseous phases, and over a range of length and time scales. Any phenomenological prediction would, therefore, require a multi-phase-scale approach. Principles of volume averaging are applied to equations of conservation to obtain single-field formulations. These are then solved with appropriate interface tracking techniques such as Enthalpy, Level-set, Volume-of-fluid and Immersed-boundary methods. The framework is built up on a standard pressure based incompressible fluid flow solver (SIMPLER algorithm) and coupled modeling strategies are proposed to address the interfacial dynamics. A two-dimensional framework is considered with a fixed-grid Cartesian co-ordinate system. Scaling analyses are performed to bring out the relative effects of various competing parameters in order to obtain further insights into this complex phenomenon. The numerical results and scaling predictions are validated against experimental observations published in literature. In literature, numerical predictions of microporosity mainly include criteria based models based on empirical relations and deterministic/stochastic models based on diffusion driven growth assuming spherical bubbles. The dynamic evolution of non-spherical bubble-metal interface in a three-phase system is yet to be captured. Moreover, several in-situ experiments have shown elongated bubble shapes during the engulfment phase, therefore a criterion to define the dependence on cooling rates and the resulting bubble morphology can possibly deliver further practical insights. We propose a numerical model for hydrogen bubble growth, its movement and subsequent engulfment by a solidifying front, combining the features of level-set and enthalpy methods for tracking bubble-metal and solid-liquid interfaces, respectively. The influx of hydrogen into heterogeneously nucleated bubbles results in growth of bubbles to sizes up to a few hundreds of microns. In the first part of this numerical study, a methodology based on the level-set approach is developed to simultaneously capture…" @default.
• W1959289018 created "2016-06-24" @default.
• W1959289018 creator A5050924241 @default.
• W1959289018 date "2012-04-01" @default.
• W1959289018 modified "2023-09-24" @default.
• W1959289018 title "Multi-Phase Modeling Of Microporosity And Microstructures During Solidification Of Aluminum Alloys" @default.
• W1959289018 hasPublicationYear "2012" @default.
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