The mechanisms of formation and prevention of channel segregation during alloy solidification

Using a base chilled configuration, conditions for the formation and prevention of segregation channels are studied in the ammonium chloride-water and lead-tin systems. Such channels develop when the rejected solute is less dense than the solvent and are therefore a result of density inversion, but slow (less than 5 rpm) rates of mold rotation, about axes inclined to the vertical by 20 to 30 deg, throughout the time of solidification, effectively prevent the formation or propagation of these channels. In experiments with artificially created or blocked channels, a simultaneous solute plume in the bulk liquid must be present in order for a channel to develop. The results indicate that channels originate not within the dendritic array, but immediately ahead of the growth front as a result of perturbation from the less dense boundary layer into the bulk liquid. The effect of mold movement is to translate laterally the bulk liquid relative to the growth front so that perturbations are sheared off. The nature of the liquid movement is considered and shown to be a function of the mold dimensions.