Dominant dimensionless parameters controlling solute transfer during electromagnetic cold crucible melting and directional solidifying TiAl alloys

Electromagnetic cold crucible (EMCC) is widely applied to melt and solidify refractory and reactive materials, the electromagnetically driven flow in the melt leads to intensive transfer behaviors of solute and strongly affects crystal growth. In this paper, a 3-D numerical model for predicting the solute transfer behaviors in a square EMCC used for melting and directional solidifying was established and verified. A two-way coupling method was proposed to calculate the electromagnetically driven flow and its effects on solute transfer. Influences of the dominant dimensionless parameters on solute transfer behaviors in the EMCC were examined, those being the Hartman (Ha), magnetic Reynolds (Rω), coils-melt position (h) and the ratio of the melt height to length (H/L) numbers. Results demonstrate that the solute segregation tends to appear in the vicinity of solid/liquid (S/L) interface, the top of meniscus and the confluence of two eddies near the wall of meniscus. The solute segregation degree (Se=Cmax−CminC0) decreases with increasing Ha, which contributes to the augment of flow intensity in the melt. Moreover, the Se decreases linearly with increasing Rω owing to the intensive oscillation of melt flow. The enhanced EM coupling with increasing H/L results in the decrease of Se in the melt. However, the solute segregation in the corner of the meniscus gradually aggravates with increasing h, which results from the enlarging of lower eddies in the bulk of the melt. The solute segregation in the vicinity of S/L interface is strongly influenced by the scale and the flow intensity of lower eddies, which could change the phase transition path and morphology of crystal during directional solidification process. Larger value of Ha, Rω and H/L, as well as smaller h are beneficial to alleviate the solute segregation in the vicinity of S/L interface.