Simulation of the Composition and Cooling Rate Effects on the Solidification Path of Casting Aluminum Alloys
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Simulation of the Composition and Cooling Rate Effects on the Solidification Path of Casting Aluminum Alloys F. Zhang1 • C. Zhang1 • S.-M. Liang1 • D. C. Lv1 • S. L. Chen1 • W. S. Cao1
Submitted: 25 May 2020 / in revised form: 9 July 2020 ASM International 2020
Abstract Solidification simulations were carried out for casting aluminum alloy A356 using PanSolidification module of Pandat software which enables consideration of back diffusion in the solid during solidification. The casting microstructure features including the solidified phases, phase fractions, and secondary dendrite arm spacing (SDAS) were simulated. The simulated results explain the experimental observations reasonably well. High throughput calculation was performed to understand the effects of alloy composition and cooling rate on the formation of the intermetallic phases and SDAS in the casting microstructure. The role of Mn in eliminating the formation of detrimental b-AlFeSi phase was also simulated and discussed. Keywords CALPHAD cooling rate PandatTM software phase diagram solidification
This article is an invited paper selected from presentations at ‘‘PSDK XIV: Phase Stability and Diffusion Kinetics—Gibbs: Phase Equilibria, Diffusion and Materials Design’’ held during MS&T’19, September 29–October 3, 2019, in Portland, Oregon. The special sessions were dedicated to honor Dr. Patrice Turchi, recipient of the ASM International 2019 J. Willard Gibbs Phase Equilibria Award ‘‘for outstanding and pioneering contributions in the application of first-principles, quantum-mechanical calculations to the modeling of phase equilibria and thermodynamic behavior of alloys.’’ It has been expanded from its original presentation. & F. Zhang [email protected] 1
CompuTherm LLC, 8401 Greenway Blvd, STE248, Middleton, WI 53562,
1 Introduction The CALPHAD method, which stands for CALculation of PHAse Diagrams, has become a widely used method for effectively calculating phase diagrams of multi-component systems in the past a few decades.[1–4] The essence of this approach is to obtain self-consistent thermodynamic descriptions of the lower-order systems in terms of known thermodynamic and phase equilibrium data. The advantage of this method is that the separately measured phase diagrams and thermodynamic properties can be represented by a self-consistent thermodynamic database of the material system in question. More importantly, a thermodynamic database for a higher-order system can be obtained from those of the lower order systems via an extrapolation method.[5] This thermodynamic database enables us to calculate phase diagrams and thermodynamic properties of a multi-component system that are experimentally unavailable. Currently, the CALPHAD approach is the only method that can be used to obtain multi-component phase diagrams with enough accuracy for practical applications without the need of exhaustive experimental work.[6] The success of the CALPHAD approach depends on the availability of both software and phase-base property databases deve
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