In the present work, solidification of a hyper-eutectic ammonium chloride solution in a bottom-cooled cavity (i.e. with stable thermal gradient) is numerically studied. A Rayleigh number based criterion is developed, which determines the conditions favorable for freckles formation. This criterion, when expressed in terms of physical properties and process parameters, yields the condition for plume formation as a function of concentration, liquid fraction, permeability, growth rate of a mushy layer, and thermophysical properties. Subsequently, numerical simulations are performed for cases with initial and boundary conditions favoring freckle formation. The effects of parameters, such as cooling rate and initial concentration, on the formation and growth of freckles are investigated. It was found that a high cooling rate produced larger and more defined channels which are retained for a longer durations. Similarly, a lower initial concentration of solute resulted in fewer but more pronounced channels. The number and size of channels are also found to be related to the mushy zone thickness. The trends predicted with regard to the variation of number of channels with time under different process conditions are in accordance with the experimental observations reported in the literature.
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Research Papers
Numerical Studies on Channel Formation and Growth During Solidification: Effect of Process Parameters
Jayesh Jain,
Jayesh Jain
Department of Mechanical Engineering,
Indian Institute of Science
, Bangalore 560012, India
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Arvind Kumar,
Arvind Kumar
Department of Mechanical Engineering,
Indian Institute of Science
, Bangalore 560012, India
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Pradip Dutta
Pradip Dutta
Department of Mechanical Engineering,
e-mail: pradip@mecheng.iisc.ernet.in
Indian Institute of Science
, Bangalore 560012, India
Search for other works by this author on:
Jayesh Jain
Department of Mechanical Engineering,
Indian Institute of Science
, Bangalore 560012, India
Arvind Kumar
Department of Mechanical Engineering,
Indian Institute of Science
, Bangalore 560012, India
Pradip Dutta
Department of Mechanical Engineering,
Indian Institute of Science
, Bangalore 560012, Indiae-mail: pradip@mecheng.iisc.ernet.in
J. Heat Transfer. Apr 2007, 129(4): 548-558 (11 pages)
Published Online: October 13, 2006
Article history
Received:
February 11, 2006
Revised:
October 13, 2006
Citation
Jain, J., Kumar, A., and Dutta, P. (October 13, 2006). "Numerical Studies on Channel Formation and Growth During Solidification: Effect of Process Parameters." ASME. J. Heat Transfer. April 2007; 129(4): 548–558. https://doi.org/10.1115/1.2709660
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