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<p>Ti–6Al–4V titanium alloys are widely utilized in aerospace and high-performance engineering applications due to their exceptional strength and corrosion resistance. However, during the vacuum arc remelting (VAR) process, especially for large-scale ingots, complex heat transfer and aluminum volatilization can induce segregation and microstructural control challenges, posing significant difficulties for solidification management. In this study, a three-dimensional numerical simulation model incorporating actual process parameters was developed to systematically analyze the coupled evolution of thermal fields, solidification behavior, microstructural morphology, and elemental distribution. The simulation successfully reproduced the progressive transformation of the molten pool morphology from shallow-flat to U-shaped and V-shaped configurations, and identified three characteristic regions: a fine-grained and columnar zone at the bottom, inward-converging columnar grains in the midsection, and an extended equiaxed grain region at the top resulting from reduced cooling during hot topping. The results indicated that increasing melting rates deepened the molten pool, reduced the solid fraction, thickened the mushy zone, and aligned grain orientations more closely with the principal heat flow. Aluminum showed central depletion, peripheral enrichment, and significant volatilization at the ingot top. The simulation outcomes were in good agreement with experimental observations, validating the model’s accuracy and applicability. This study provides valuable insights for optimizing VAR processes, enhancing microstructural uniformity, and reducing defect risks.</p>

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Three-Dimensional Simulation and Experimental Validation of Solidification Behavior in Large-Scale Vacuum Arc Remelted Ti–6Al–4V Alloy Ingots

  • 期刊论文

  • 发表日期：

    2026年1月26日

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  • Meichen Wang,
  • Shuangjie Chu,
  • Qifei Zhang,
  • Gaofei Liang,
  • Haiyan Zhao,
  • Xinhua Min,
  • Qingtong Meng,
  • Bo Mao

摘要

Ti–6Al–4V titanium alloys are widely utilized in aerospace and high-performance engineering applications due to their exceptional strength and corrosion resistance. However, during the vacuum arc remelting (VAR) process, especially for large-scale ingots, complex heat transfer and aluminum volatilization can induce segregation and microstructural control challenges, posing significant difficulties for solidification management. In this study, a three-dimensional numerical simulation model incorporating actual process parameters was developed to systematically analyze the coupled evolution of thermal fields, solidification behavior, microstructural morphology, and elemental distribution. The simulation successfully reproduced the progressive transformation of the molten pool morphology from shallow-flat to U-shaped and V-shaped configurations, and identified three characteristic regions: a fine-grained and columnar zone at the bottom, inward-converging columnar grains in the midsection, and an extended equiaxed grain region at the top resulting from reduced cooling during hot topping. The results indicated that increasing melting rates deepened the molten pool, reduced the solid fraction, thickened the mushy zone, and aligned grain orientations more closely with the principal heat flow. Aluminum showed central depletion, peripheral enrichment, and significant volatilization at the ingot top. The simulation outcomes were in good agreement with experimental observations, validating the model’s accuracy and applicability. This study provides valuable insights for optimizing VAR processes, enhancing microstructural uniformity, and reducing defect risks.