A two-phase volume-averaged continuum model is presented that quantifies macrosegregation formation during solidification of metallic alloys caused by deformation of the dendritic network and associated melt flow in the coherent part of the mushy zone. Also, the macrosegregation formation associated with the solidification shrinkage (inverse segregation) is taken into account. Based on experimental evidence established elsewhere, volumetric viscoplastic deformation (densification/dilatation) of the coherent dendritic network is included in the model. While the thermomechanical model previously outlined (M. M'Hamdi, A. Mo, and C.L. Martin: Metall. Mater. Trans. A, 2002, vol. 33A, pp. 2081 has been used to calculate the temperature and velocity fields associated with the thermally induced deformations and shrinkage driven melt flow, the solute conservation equation including both the liquid and a solid volume-averaged velocity is solved in the present study. In modeling examples, the macrosegregation formation caused by mechanically imposed as well as by thermally induced deformations has been calculated. The modeling results for an Al-4 wt pct Cu alloy indicate that even quite small volumetric strains (ഠ2 pct), which can be associated with thermally induced deformations, can lead to a macroscopic composition variation in the final casting comparable to that resulting from the solidification shrinkage induced melt flow. These results can be explained by the relatively large volumetric viscoplastic deformation in the coherent mush resulting from the applied constitutive model, as well as the relatively large difference in composition for the studied Al-Cu alloy in the solid and liquid phases at high solid fractions at which the deformation takes place.

An experimental set-up for investigating macrosegregation formation due to deformation of an isotropic metallic mushy zone is presented. In the experiment, a semisolid Al-5.9wt%Cu sample is isothermally and non-uniformly compressed. Concentration and eutectic fraction are measured along selected lines, after quenching the sample. Results show that interdendritic liquid is pressed out of the central part of the sample to its outer part, increasing the concentration in this region. The experimental test is then addressed by a two-phase continuum model recently presented elsewhere. The modelling results show the same tendencies observed experimentally, although local variations in composition are not well correlated. Suggestions for future work are made.

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