Analysis of yield rate in single crystal casting process using an engineering simulation model

A 2-D engineering model for grain selection has been developed taking the columnar dendrite growth theory into consideration. After evaluating this model via a unidirectional solidification experiment, the single-crystal casting process was simulated. Since the time required for calculation is rather short, a statistical analysis has been performed for the first time. The yield rate of well-oriented single crystal is increased by increasing the initial number of grains on the chill plate. However, the yield rate does not exceed approximately 90%. A detailed investigation of the formation mechanism of misorientation has revealed two possible processes (Type A and Type B) that may occur during single crystal casting process.