Modeling and simulation of phase-transitions in multicomponent aluminum alloy casting

Abstract

The casting process of aluminum products involves the spatial distribution of alloying elements. It is essential that these elements are uniformly distributed in order to guarantee reliable and consistent products. This requires a good understanding of the main physical mechanisms that affect the solidification, in particular the thermodynamic description and its coupling to the transport processes of heat and mass that take place. The continuum modeling is reviewed and methods for handling the thermodynamics component of multi-element alloys are proposed. Savings in data-storage and computing costs on the order of 100 or more appear possible, when a combination of data-reduction and data-representation methods is used. To test the new approach a simplified model was proposed and shown to qualitatively capture the evolving solidification front.