In situ X-ray radiography study on the impact of forced melt convection on solidification processes

In this paper, we present experimental investigations focusing on the question how natural and forced convection influence the microstructure formation in solidifying alloys.
In situ visualization of the solidification of Ga–25wt%In alloys was carried out by means of X-ray radioscopy. An electromagnetically driven flow was produced inside the solidifying liquid by a rotating wheel with two parallel disks containing at their inner sides a set of permanent NdFeB magnets with alternating polarisation [1, 2]. Rotation speeds of the magnetic wheel were chosen in the range of 10 – 80 revolutions per minute resulting in local flow velocities between 0.5 and 1.5 mm/s in the area just ahead of the solidification front. The melt flow is almost perpendicular with respect to the growth direction of the dendrites.
The forced convection induces a redistribution of solute concentration, re-orientation of the dendritic structure, changes of primary and secondary branching, and leads to a formation of segregation channels. Flow patterns, dendrite morphologies and tip velocities were quantified by image analysis and related to the experimental conditions. In principle, the forced flow is an external operational parameter that can be used to control the final microstructure. However, the optimization of the microstructure by electromagnetic flow control is a complex task which requires a deep understanding of the complex interplay between melt flow and solidification process.