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<p>Thin-walled aluminum alloys, prized for their high specific strength, are critical to modern aerospace and other advanced industries. Counter-gravity casting (CGC) is a premier method for fabricating such components, where precise control over solidification microstructure is paramount. However, this control is challenged by the complex interplay of forced and natural convection during solidification. This study employs a coupled multiple-relaxation-time lattice Boltzmann (D2Q9) and quantitative phase-field model to simulate dendritic growth in a thin-walled Al-0.576wt.%Cu alloy. Simulations reveal that convection disrupts dendritic symmetry: for equiaxed crystals, solute plumes and asymmetric arm growth are observed, while for columnar dendrites, an optimal applied force exists that refines the microstructure without compromising economic viability. Furthermore, forced convection consistently reduces the inclination angle of primary dendrites. These findings, validated against experimental data, elucidate the micro-mechanisms of dendritic growth under convection, providing critical theoretical guidance for optimizing CGC processes.</p>

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Effects of natural and forced convections on dendritic growth in thin-walled Al-Cu alloy by counter-gravity casting: A phase-field lattice-Boltzmann study

  • 期刊论文

  • 发表日期：

    2026年5月20日

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  • Jia-tuo An,
  • Da-fan Du,
  • Li-jun Zhang,
  • An-ping Dong,
  • Bao-de Sun

摘要

Thin-walled aluminum alloys, prized for their high specific strength, are critical to modern aerospace and other advanced industries. Counter-gravity casting (CGC) is a premier method for fabricating such components, where precise control over solidification microstructure is paramount. However, this control is challenged by the complex interplay of forced and natural convection during solidification. This study employs a coupled multiple-relaxation-time lattice Boltzmann (D2Q9) and quantitative phase-field model to simulate dendritic growth in a thin-walled Al-0.576wt.%Cu alloy. Simulations reveal that convection disrupts dendritic symmetry: for equiaxed crystals, solute plumes and asymmetric arm growth are observed, while for columnar dendrites, an optimal applied force exists that refines the microstructure without compromising economic viability. Furthermore, forced convection consistently reduces the inclination angle of primary dendrites. These findings, validated against experimental data, elucidate the micro-mechanisms of dendritic growth under convection, providing critical theoretical guidance for optimizing CGC processes.