A phase-field simulation of the solidification process under compression

Semi-solid metal forming processes cover a wide variety of technologies in manufacturing, generally leading to non-dendritic microstructures typified by rosette-like or spherical grains. With the contemporary experimental methods, researchers still cannot completely understand the formation of such microstructures. However, as a process coupled with dendritic growth, deformation and flow, the microstructural evolution during the semisolid deformation has been scarcely simulated. With the vector-valued phase-field method, two-phase flow model and an innovative design of boundary conditions, the current research numerically compressed a single dendrite into a less dendritic polycrystalline structure. The resulting microstructure was consistent with the metallographic analysis and the simulation enables a clear observation of the whole process: the ripening transformed the highly branched shape into a less dendritic one; the subsequent deformation crushed the dendrite into a stubby structure; eventually, the deformation caused the boundaries inside this structure, dividing the solid into multiple grains. The analysis on the boundaries inside the deformed solid offered further insight into the formation of non-dendritic structures. These boundaries showed a tendency towards melting with increasing misorientation, demonstrating the possibility of the grain boundary wetting, which was considered as the source of the fragmentation when the dendrite undergoes deformation, but is hard to validate in situ even with the cutting-edge X-ray imaging technique. (c) 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).