Institute of Metals Division - A Computer Analysis of Inverse Segregation (TN)

In a previous communication by one of us,1 a theory of inverse segregation was presented by which the maximum segregation and segregation distribution throughout a unidirectionally solidified, binary-alloy ingot could be calculated. The theory, which is based on the mechanism of volume contraction and interdendritic flow, quantitatively accounts for the observed maximum segregation in the A1 (rich)-CU' and Al-Zn2 alloy systems, and for the segregation distribution along the ingot lengths for the A1-Cu system.''4 One of the drawbacks to a more extensive use of the segregation equations is their complexity, particularly for the calculation of the segregation distribution throughout the length of the ingot, involving long tedious numerical calculations to obtain the segregation. Computer pro- grams, written in Fortran II for use on an IBM 1620 computer, have been developed by the authors (and are available from them), providing quick and accurate methods for the determination of the theoretical maximum segregation in any binary-alloy system, and also for the segregation distribution in any unidirectionally solidified binary-alloy ingot. The segregation distribution is controlled by the lengths of the various solidification zones'74 which are in turn controlled by the cooling rate, and are determined from temperature-distribution curves obtained during solidification. The theoretical segregation distributions shown in Fig. 1 illustrate the effect of the zone lengths on the distribution Curve 1, indicative of a slowly cooled ingot, represents an ingot having long solidification zones, while Curve 2, indicative of a rapidly cooled ingot, represents an ingot having relatively short zones. Although these distributions are calculated for an A1-10 pct Cu ingot, the shape of the distribution would be similar for any binary-alloy ingot. These curves show clearly why early workers obtained results which indicated that the maximum (chill-face) segregation approached zero at very fast cooling rates.3 Actually, the maximum segregation is independent of cooling rate,' but even at short distances from the chill face the amount of segregation drops considerably, particularly in a rapidly cooled ingot, making it very difficult to establish the amount of segregation occurring at the chill-face. The authors would like to thank Dr. J. A. Goldak for his assistance in the preparation of the programs. The financial assistance of the Steel Co. of Canada and of the National Research Council of Canada in the form of Scholarships to one of us (J. R. Cahoon) is gratefully acknowledged.