Development and validation of a numerical model for intermetallic layer growth during composite casting of Cu-Al-compounds

A numerical model is developed and implemented into the open-source CFD-code OpenFOAM to predict the formation and thickness of composite layers, which grow during the composite casting of Cu and Al. The growth of AlxCuy phases is calculated based on a reaction-diffusion model, comprising the elements diffusion, thermodynamic properties and reaction rates at the phase boundaries. The influence of melt flow on the composite layer structure is considered by advection of intermetallic phases during melt flow and solidification. The implemented model is validated via an experimental setup. Comparing the experimentally and numerically determined composite layer structures, a good agreement between them is observed and the suitability of the implemented model to predict the intermetallic layer structure is proven. Furthermore, the results show that the growth of the Al2Cu phase is the dominant process during the composite layer formation, while the thicknesses of the other layers remains almost constant over the immersion time.     «

A numerical model is developed and implemented into the open-source CFD-code OpenFOAM to predict the formation and thickness of composite layers, which grow during the composite casting of Cu and Al. The growth of AlxCuy phases is calculated based on a reaction-diffusion model, comprising the elements diffusion, thermodynamic properties and reaction rates at the phase boundaries. The influence of melt flow on the composite layer structure is considered by advection of intermetallic phases during...     »