Sensitivity of mesh spacing on simulating macrosegregation during directional solidification of a superalloy

P. K. Sung, David R Poirier, S. D. Felicelli

Research output: Contribution to journalArticle

16 Citations (Scopus)

Abstract

The sensitivity of mesh spacing on simulations of macrosegregation, particularly 'freckles', during vertical directional solidification of a superalloy in a rectangular mold was systematically analyzed to achieve accurate predictions in finite element calculations. It was observed that a coarser mesh spacing in the x-direction horizontal tends to minimize the simulated macrosegregation, whereas a coarser mesh spacing in the y-direction vertical artificially tends to make the system appear to have more macrosegregation. When solidification conditions either lead to a well-established freckling case or to a well-established non-freckling case, the simulated results are not sensitive to the mesh spacing provided the elements are no larger than about 2d1 by 2 D/V and 3d1 by 4 D/V respectively, where d1 is the primary dendrite arm spacing, D is the diffusivity of the alloy solute with the smallest diffusivity in the liquid, and V is the growth rate. However, when solidification conditions are very close to the transition between freckling and no freckling, the simulated results are sensitive to the mesh spacing, especially in the y-direction. Based on the mesh sensitivity analysis from the two-dimensional simulations of rectangular castings of Rene N5, the mesh with element dimensions no larger than 2d1 in the x-direction and 1.5 D/V in the y-direction are recommended as the most stringent element size.

Original languageEnglish (US)
Pages (from-to)357-370
Number of pages14
JournalInternational Journal for Numerical Methods in Fluids
Volume35
Issue number3
DOIs
StatePublished - Feb 15 2001

Fingerprint

Superalloy
heat resistant alloys
Solidification
Superalloys
Spacing
mesh
spacing
Mesh
sensitivity
y direction
x direction
Sensitivity analysis
Diffusivity
solidification
diffusivity
Vertical
Tend
Liquids
Dendrite
sensitivity analysis

Keywords

  • Dendritic single crystal
  • Directional solidification
  • Freckles
  • Macrosegregation
  • Mesh spacing

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Safety, Risk, Reliability and Quality
  • Applied Mathematics
  • Computational Theory and Mathematics
  • Computer Science Applications
  • Computational Mechanics
  • Mechanics of Materials

Cite this

Sensitivity of mesh spacing on simulating macrosegregation during directional solidification of a superalloy. / Sung, P. K.; Poirier, David R; Felicelli, S. D.

In: International Journal for Numerical Methods in Fluids, Vol. 35, No. 3, 15.02.2001, p. 357-370.

Research output: Contribution to journalArticle

@article{b5885acd68da4151814059dab174d935,
title = "Sensitivity of mesh spacing on simulating macrosegregation during directional solidification of a superalloy",
abstract = "The sensitivity of mesh spacing on simulations of macrosegregation, particularly 'freckles', during vertical directional solidification of a superalloy in a rectangular mold was systematically analyzed to achieve accurate predictions in finite element calculations. It was observed that a coarser mesh spacing in the x-direction horizontal tends to minimize the simulated macrosegregation, whereas a coarser mesh spacing in the y-direction vertical artificially tends to make the system appear to have more macrosegregation. When solidification conditions either lead to a well-established freckling case or to a well-established non-freckling case, the simulated results are not sensitive to the mesh spacing provided the elements are no larger than about 2d1 by 2 D/V and 3d1 by 4 D/V respectively, where d1 is the primary dendrite arm spacing, D is the diffusivity of the alloy solute with the smallest diffusivity in the liquid, and V is the growth rate. However, when solidification conditions are very close to the transition between freckling and no freckling, the simulated results are sensitive to the mesh spacing, especially in the y-direction. Based on the mesh sensitivity analysis from the two-dimensional simulations of rectangular castings of Rene N5, the mesh with element dimensions no larger than 2d1 in the x-direction and 1.5 D/V in the y-direction are recommended as the most stringent element size.",
keywords = "Dendritic single crystal, Directional solidification, Freckles, Macrosegregation, Mesh spacing",
author = "Sung, {P. K.} and Poirier, {David R} and Felicelli, {S. D.}",
year = "2001",
month = "2",
day = "15",
doi = "10.1002/1097-0363(20010215)35:3<357::AID-FLD99>3.0.CO;2-9",
language = "English (US)",
volume = "35",
pages = "357--370",
journal = "International Journal for Numerical Methods in Fluids",
issn = "0271-2091",
publisher = "John Wiley and Sons Ltd",
number = "3",

}

TY - JOUR

T1 - Sensitivity of mesh spacing on simulating macrosegregation during directional solidification of a superalloy

AU - Sung, P. K.

AU - Poirier, David R

AU - Felicelli, S. D.

PY - 2001/2/15

Y1 - 2001/2/15

N2 - The sensitivity of mesh spacing on simulations of macrosegregation, particularly 'freckles', during vertical directional solidification of a superalloy in a rectangular mold was systematically analyzed to achieve accurate predictions in finite element calculations. It was observed that a coarser mesh spacing in the x-direction horizontal tends to minimize the simulated macrosegregation, whereas a coarser mesh spacing in the y-direction vertical artificially tends to make the system appear to have more macrosegregation. When solidification conditions either lead to a well-established freckling case or to a well-established non-freckling case, the simulated results are not sensitive to the mesh spacing provided the elements are no larger than about 2d1 by 2 D/V and 3d1 by 4 D/V respectively, where d1 is the primary dendrite arm spacing, D is the diffusivity of the alloy solute with the smallest diffusivity in the liquid, and V is the growth rate. However, when solidification conditions are very close to the transition between freckling and no freckling, the simulated results are sensitive to the mesh spacing, especially in the y-direction. Based on the mesh sensitivity analysis from the two-dimensional simulations of rectangular castings of Rene N5, the mesh with element dimensions no larger than 2d1 in the x-direction and 1.5 D/V in the y-direction are recommended as the most stringent element size.

AB - The sensitivity of mesh spacing on simulations of macrosegregation, particularly 'freckles', during vertical directional solidification of a superalloy in a rectangular mold was systematically analyzed to achieve accurate predictions in finite element calculations. It was observed that a coarser mesh spacing in the x-direction horizontal tends to minimize the simulated macrosegregation, whereas a coarser mesh spacing in the y-direction vertical artificially tends to make the system appear to have more macrosegregation. When solidification conditions either lead to a well-established freckling case or to a well-established non-freckling case, the simulated results are not sensitive to the mesh spacing provided the elements are no larger than about 2d1 by 2 D/V and 3d1 by 4 D/V respectively, where d1 is the primary dendrite arm spacing, D is the diffusivity of the alloy solute with the smallest diffusivity in the liquid, and V is the growth rate. However, when solidification conditions are very close to the transition between freckling and no freckling, the simulated results are sensitive to the mesh spacing, especially in the y-direction. Based on the mesh sensitivity analysis from the two-dimensional simulations of rectangular castings of Rene N5, the mesh with element dimensions no larger than 2d1 in the x-direction and 1.5 D/V in the y-direction are recommended as the most stringent element size.

KW - Dendritic single crystal

KW - Directional solidification

KW - Freckles

KW - Macrosegregation

KW - Mesh spacing

UR - http://www.scopus.com/inward/record.url?scp=0035864598&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=0035864598&partnerID=8YFLogxK

U2 - 10.1002/1097-0363(20010215)35:3<357::AID-FLD99>3.0.CO;2-9

DO - 10.1002/1097-0363(20010215)35:3<357::AID-FLD99>3.0.CO;2-9

M3 - Article

VL - 35

SP - 357

EP - 370

JO - International Journal for Numerical Methods in Fluids

JF - International Journal for Numerical Methods in Fluids

SN - 0271-2091

IS - 3

ER -