Benchmark Al-Cu Solidification Experiments in Microgravity and on Earth

Predicting macrosegregation and grain structure, including the columnar to equiaxed transition (CET), in alloy solidification is an ongoing challenge. Gravity-driven melt convection and transport of unattached solid grains complicate such efforts. Cylindrical samples of aluminum alloys containing 4, 10, and 18 wt pct copper are solidified from the bottom upwards on Earth and in microgravity conditions aboard the International Space Station. The chosen alloys possess primary solid densities that are greater than, equal to, and less than their melt densities promoting different gravity-driven solid transport phenomena. Significant differences in grain structure are observed between microgravity and terrestrial samples. All microgravity samples are entirely equiaxed, while the terrestrial samples exhibit a CET. The columnar grains near the cooled surface in the terrestrial samples can only be attributed to melt convection. The Al-4 wt pct Cu terrestrial sample shows evidence of grain sedimentation, while the Al-18 wt pct Cu terrestrial sample exhibits the effects of grain floatation. Measurements of eutectic fraction and solute concentration in the samples show inverse segregation due to shrinkage-driven flow in all samples. Terrestrially solidified samples have areas of high solute concentration that are not uniformly distributed over the diameter, indicating the presence of melt convection. The eutectic and macrosegregation measurements generally have good correspondence. Temperature, grain structure, eutectic fraction, and macrosegregation data are presented as benchmark data to validate future modeling efforts. Heat flux boundary conditions on the sample are determined using thermal modeling. Thermal process parameters are calculated for all samples.