Multiscale modeling of the influence of Fe content in a Al-Si-Cu alloy on the size distribution of intermetallic phases and micropores
- Department of Materials, Imperial College London, South Kensington Campus, Prince Consort Road, London SW7 2AZ (United Kingdom)
- Materials Research and Advanced Engineering Department, Ford Research Laboratory, Dearborn, Michigan 48121-2053 (United States)
A multiscale model was developed to simulate the formation of Fe-rich intermetallics and pores in quaternary Al-Si-Cu-Fe alloys. At the microscale, the multicomponent diffusion equations were solved for multiphase (liquid-solid-gas) materials via a finite difference framework to predict microstructure formation. A fast and robust decentered plate algorithm was developed to simulate the strong anisotropy of the solid/liquid interfacial energy for the Fe-rich intermetallic phase. The growth of porosity was controlled by local pressure drop due to solidification and interactions with surrounding solid phases, in addition to hydrogen diffusion. The microscale model was implemented as a subroutine in a commercial finite element package, producing a coupled multiscale model. This allows the influence of varying casting conditions on the Fe-rich intermetallics, the pores, and their interactions to be predicted. Synchrotron x-ray tomography experiments were performed to validate the model by comparing the three-dimensional morphology and size distribution of Fe-rich intermetallics as a function of Fe content. Large platelike Fe-rich {beta} intermetallics were successfully simulated by the multiscale model and their influence on pore size distribution in shape castings was predicted as a function of casting conditions.
- OSTI ID:
- 21476155
- Journal Information:
- Journal of Applied Physics, Vol. 107, Issue 6; Other Information: DOI: 10.1063/1.3340520; (c) 2010 American Institute of Physics; ISSN 0021-8979
- Country of Publication:
- United States
- Language:
- English
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Related Subjects
75 CONDENSED MATTER PHYSICS
SUPERCONDUCTIVITY AND SUPERFLUIDITY
ALUMINIUM
ANISOTROPY
CASTING
DIFFUSION
DIFFUSION EQUATIONS
FINITE DIFFERENCE METHOD
FINITE ELEMENT METHOD
HYDROGEN
INTERMETALLIC COMPOUNDS
IRON
MICROSTRUCTURE
MORPHOLOGY
POROSITY
POROUS MATERIALS
PRESSURE DROP
SILICON
SOLIDIFICATION
X-RAY RADIOGRAPHY
ALLOYS
CALCULATION METHODS
DIFFERENTIAL EQUATIONS
ELEMENTS
EQUATIONS
FABRICATION
INDUSTRIAL RADIOGRAPHY
ITERATIVE METHODS
MATERIALS
MATERIALS TESTING
MATHEMATICAL SOLUTIONS
METALS
NONDESTRUCTIVE TESTING
NONMETALS
NUMERICAL SOLUTION
PARTIAL DIFFERENTIAL EQUATIONS
PHASE TRANSFORMATIONS
SEMIMETALS
TESTING
TRANSITION ELEMENTS