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Full Description
Solidification is one of the oldest processes for producing complex shapes for applications ranging from art to industry, and remains as one of the most important commercial processes for many materials. Since the 1980s, numerous fundamental developments in the understanding of solidification processes and microstructure formation have come from both analytical theories and the application of computational techniques using commonly available powerful computers. This book integrates these developments in a comprehensive volume that also presents and places them in the context of more classical theories. This second edition highlights the key concepts within each chapter to help guide the reader through the most important aspects of the topics. The figures are now in color, in order to improve the visualization of phenomena and concepts. Recent important developments in the field since the first edition was published have also been added.
The three-part text is aimed at graduate and professional engineers. The first part, Fundamentals and Macroscale Phenomena, presents the thermodynamics of solutions and then builds on that subject to motivate and describe equilibrium phase diagrams. Transport phenomena are discussed next, focusing on the issues of most importance to liquid-solid phase transformations, then moving on to describing in detail both analytical and numerical approaches to solving such problems. The second part, Microstructure, employs these fundamental concepts for the treatment of nucleation, dendritic growth, microsegregation, eutectic and peritectic solidification, and microstructure competition. This part concludes with a chapter describing the coupling of macro- and microscopic phenomena in microstructure development. The third and final part describes various types of Defects that may occur, with emphasis on porosity, hot tearing and macrosegregation, presented using the modeling tools and microstructure descriptions developed earlier.
Contents
Overview
Introduction
Solidification processes
References
PART 1 FUNDAMENTALS AND MACROSCALE PHENOMENA
Thermodynamics
Introduction
Thermodynamics of unary systems
Binary alloys
Departure from equilibrium
Exercises
References
Phase diagrams
Motivation
Binary systems
Ternary systems
Exercises
References
Balance Equations
Introduction
Mass balance
Momentum balance
Energy balance
Solute balance in multicomponent systems
Scaling
Exercises
References
Analytical solutions for solidification
Introduction
Solidification in a superheated melt
Solidification in an undercooled melt
The effect of curvature
Exercises
References
Numerical methods for solidification
Introduction
Heat conduction without phase change
Heat conduction with phase change
Fluid flow
Optimization and inverse methods
Exercises
References
PART II MICROSTRUCTURE
Nucleation
Introduction
Homogeneous nucleation
Heterogeneous nucleation
Mechanisms for grain refinement
Exercises
References
Dendritic growth
Introduction
Free growth
Constrained growth
Growth of a needle crystal
Convection and dendritic growth
Phase-field methods
Exercises
References
Eutectics, peritectics and microstructure selection
Introduction
Eutectics
Peritectics
Phase selection and coupled zone
Exercises
References
Microsegregation and homogenization
Introduction
1-D microsegregation models for binary alloys
Homogenization and solution treatment
Multicomponent alloys
Exercises
References
Macro- and microstructures
Introduction
Equiaxed grains growing in a uniform temperature field
Grains nucleating and growing in a thermal gradient
Columnar grains
Columnar-to-Equiaxed Transition
Micro-macroscopic models
Exercises
References
PART III DEFECTS
Porosity
Introduction
Governing equations
Interdendritic fluid flow and pressure drop
Thermodynamics of gases in solution
Nucleation and growth of pores
Boundary conditions
Application of the concepts
Exercises
References
Deformation during solidification and hot tearing
Introduction
Thermomechanics of castings
Deformation of the mushy zone
Hot tearing
Hot tearing criteria and models
Exercises
References
Macrosegregation
Introduction
Macrosegregation during planar front solidification
Composition field and governing equations
Macrosegregation induced by solidification shrinkage
Macrosegragation induced by fluid flow
Macrosegregation induced by solid movement
Exercises
References
