Numerical modeling of copper macro-segregation in the binary alloy Al-4Cu

Abstract

In this paper, the modeling of the solidification of Al-4Cu alloy was studied. The calculation code is developed to model the equiaxed globular solidification of the Al-4Cu alloy in a square mold. The mold walls are subjected to constant temperatures and the velocity components are equal to 0, the exchange coefficient ’H’ between the interface of the melt and the mold is estimated at 500 W/( m2 K) and the initial melt temperature ’T0’ is equal to 900 K. The resolution method used is finite differences, the upwind scheme for convective terms, and the space-centered scheme for diffusive terms. The calculated profiles are temperature, solid fraction, concentration and macro-segregation of copper. At the beginning of cooling, the solidification of the Al-4Cu alloy started in the four corners of the plate. The grains formed at the walls could not move in the studied surface. With cooling time, the solidification of the casting developed rapidly in the lower part; because, the grains formed away from the walls sedimented and accumulated in this part of the plate. On other hand, the liquid was located mainly in the upper part. The segregation of copper in the two-phase mixture is due to its continuous rejection from the solid to the liquid.