In this study, a numerical model was developed, and direct simulations were performed to predict solidification grain structures and macrosegregation based on a three-dimensional cellular automaton finite difference (CAFD) method coupled with flow calculation of natural convection and shrinkage flow. First, to evaluate the model coupled with natural convention, simulations of unidirectional solidification for Al-10wt% Mg alloy were performed. Mg-rich plumes rising in the melt were seen due to subsequent upward flow, and Mg-rich channels forming in the mushy zone were observed. Columnar grains were then formed, and they became coarse afterwards. Next, to evaluate the model coupled with shrinkage flow, simulations of casting Al-10wt% Cu alloy in a unique mold, which can form macrosegregation in the central region of the small ingot, were performed. The bridging of columnar grains formed during solidification, and the positive segregation was generated in the region below the bridging. Thus, the main factor for this macrosegregation is the shrinkage flow with bridging. From the comparison of simulation results with and without the chill for the unique mold, it was established that the shrinkage flow and the bridging of solidification structures play an important role in macrosegregation.
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