Multi-scale Modeling of Quasi-directional Solidification of a Cast Si-Rich Eutectic Alloy

Dow Corning Corporation recently examined the use of transition metal-silicon eutectics for producing melt-castable ceramic parts. These materials display good strength, wear and corrosion resistance. The near-eutectic solidification structure has significant impact on the final properties of a cast component. However, direct simulation of the cast structure at industrial scales remains a challenge. The objective of this work is to develop a multi-scale integrated solidification model that includes: density functional theory (DFT) calculations, which enable the computation of difficult-to-measure thermophysical properties; microstructural evolution simulation, which tackles nucleation eutectic growth and segregation during solidification; and casting modeling, which accounts for different boundary conditions including temperature-dependent heat transfer coefficients and geometry. The developed 3D coupled code can predict the correct morphology of the solidified composite and aid in the design and optimization of melt-cast parts based on composition and process parameters in a virtual environment. To verify the model, a mold was designed to achieve quasi-directional solidification within large regions of each casting; hypo-and hyper-eutectic Si-Cr alloys were cast into this custom mold using a vacuum tilt pour unit. Our experimental efforts focused on the quantification of the effects of process conditions on the resulting microstructure of the cast component. Local segregation was examined and compared with the model's predictions. Results are in agreement with the microstructure observed in our castings.