Freckle Formation in Pb-10% Sn Alloy under Various Solidification Conditions

Lisa Philipp; Ibrahim Sari; Menghuai Wu; Abdellah Kharicha

doi:10.1088/1757-899X/1335/1/012024

Freckle Formation in Pb-10% Sn Alloy under Various Solidification Conditions

Chair of Simulation and Modelling of Metallurgical Processes (310)

Research output: Contribution to conference › Paper › peer-review

Abstract

Freckles are macrosegregations that form during solidification of alloys.
We used a numerical model to study melt and mushy zone behavior under
thermosolutal convection and predict freckle formation under various casting
conditions. The model simulates fluid flow in a 2D square domain during upward
solidification, using a two-phase mixture approach with Boussinesq
approximation. The mushy zone is treated as a porous medium with permeability
defined by the Carman-Kozeny relation. The aim of the present study is to explore
how the effect of temperature gradient and tilted solidification front influences the
onset and development of freckles for a Pb-10% Sn alloy. The results indicate
delayed freckle formation at higher temperature gradients in a closed cavity under
otherwise identical casting conditions. However, a clear correlation between
gravity direction and freckle alignment could not be found.

Original language	English
DOIs	https://doi.org/10.1088/1757-899X/1335/1/012024
Publication status	Published - 1 Sept 2025

Access to Document

10.1088/1757-899X/1335/1/012024

Cite this

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title = "Freckle Formation in Pb-10\% Sn Alloy under Various Solidification Conditions",

abstract = "Freckles are macrosegregations that form during solidification of alloys. We used a numerical model to study melt and mushy zone behavior under thermosolutal convection and predict freckle formation under various casting conditions. The model simulates fluid flow in a 2D square domain during upward solidification, using a two-phase mixture approach with Boussinesq approximation. The mushy zone is treated as a porous medium with permeability defined by the Carman-Kozeny relation. The aim of the present study is to explore how the effect of temperature gradient and tilted solidification front influences the onset and development of freckles for a Pb-10\% Sn alloy. The results indicate delayed freckle formation at higher temperature gradients in a closed cavity under otherwise identical casting conditions. However, a clear correlation between gravity direction and freckle alignment could not be found.",

author = "Lisa Philipp and Ibrahim Sari and Menghuai Wu and Abdellah Kharicha",

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T1 - Freckle Formation in Pb-10% Sn Alloy under Various Solidification Conditions

AU - Philipp, Lisa

AU - Sari, Ibrahim

AU - Wu, Menghuai

AU - Kharicha, Abdellah

PY - 2025/9/1

Y1 - 2025/9/1

N2 - Freckles are macrosegregations that form during solidification of alloys. We used a numerical model to study melt and mushy zone behavior under thermosolutal convection and predict freckle formation under various casting conditions. The model simulates fluid flow in a 2D square domain during upward solidification, using a two-phase mixture approach with Boussinesq approximation. The mushy zone is treated as a porous medium with permeability defined by the Carman-Kozeny relation. The aim of the present study is to explore how the effect of temperature gradient and tilted solidification front influences the onset and development of freckles for a Pb-10% Sn alloy. The results indicate delayed freckle formation at higher temperature gradients in a closed cavity under otherwise identical casting conditions. However, a clear correlation between gravity direction and freckle alignment could not be found.

AB - Freckles are macrosegregations that form during solidification of alloys. We used a numerical model to study melt and mushy zone behavior under thermosolutal convection and predict freckle formation under various casting conditions. The model simulates fluid flow in a 2D square domain during upward solidification, using a two-phase mixture approach with Boussinesq approximation. The mushy zone is treated as a porous medium with permeability defined by the Carman-Kozeny relation. The aim of the present study is to explore how the effect of temperature gradient and tilted solidification front influences the onset and development of freckles for a Pb-10% Sn alloy. The results indicate delayed freckle formation at higher temperature gradients in a closed cavity under otherwise identical casting conditions. However, a clear correlation between gravity direction and freckle alignment could not be found.

U2 - 10.1088/1757-899X/1335/1/012024

DO - 10.1088/1757-899X/1335/1/012024

M3 - Paper

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