Macrosegregation Modelling of Large Sheet Ingots Including Grain Motion, Solidification Shrinkage and Mushy Zone Deformation

In the former EU-supported 4th framework programme EMPACT several large ingots were cast and characterized including detailed mapping of the chemical composition in different cross sections of the ingots. At the time of the project we did not have the modelling tools to support the measurements regarding the understanding of the different mechanisms involved in creating macrosegregation on large dimension ingots. Now, using a model specifically developed for DC-casting—Alsim, we have simulated two of these ingots cast at the research facility in Bonn. One of the ingots was grain refined—the other not. The metal distributor (combo-bag) for the non-grain refined ingot was later removed. The three different cases experienced distinctly different macrosegregation patterns and the mechanisms behind these patterns are discussed with the help of the simulation results.