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A three phase model for the mixed columnar-equiaxed solidification was proposed by the current authors [Wu and Ludwig 2006 Metall. Mater. Trans. 37A 1613-31]. The main features of the mixed columnar-equiaxed solidification are considered: the growth of the columnar dendrite trunks from the ingot surface, the nucleation and growth of the equiaxed crystals, the sedimentation of the equiaxed crystals, the thermal and solutal buoyancy flow and its interactions with the growing crystals, the solute partitioning at the solid-liquid interface during solidification, the solute transport due to melt convection and equiaxed sedimentation, the mechanical interaction/impingement between columnar and equiaxed crystals and the columnar-to-equiaxed transition (CET). However, due to the model complexity and the limited computational capability the model has not yet applied to the large steel ingots of engineering scale. This paper is going to simulate a 2.45 ton big-end-up industry steel ingot, for which some experimental results were reported [Marburg 1926 Iron Steel Inst. 113 39-176]. Here a simplified binary phase diagram for the steel (Fe-0.45 wt. %C) is considered. Comparison of the modelling results such as as-cast columnar and equiaxed zones, macrosegregation with the experimental results is made. Details about the formation sequence of the distinguished crystal zones and segregation patterns are analyzed.

Modelling macrosegregation in a 2.45 ton steel ingot