Simulation of macrosegregation in a 36-t steel ingot using a multiphase model

Macrosegregation is the major defect in large steel ingots caused by solute partitioning and melt convection during casting. In this study, a three-phase (liquid, columnar dendrites, and equiaxed grains) model is proposed to simulate macrosegregation in a 36-t steel ingot. A supplementary set of conservation equations are employed in the model such that two types of equiaxed grains, either settling or adhering to the solid shell, are well simulated. The predicted concentration agrees quantitatively with the experimental value. A negative segregation cone was located at the bottom owing to the grain settlement and solute-enriched melt leaving from the mushy zone. The interdendritic liquid flow was carefully analyzed, and the formation of A-type segregations in the mid-height of the ingot is discussed. Negative segregation was observed near the riser neck due to the specific relationship between flow direction and temperature gradient. Additionally, the as-cast macrostructure of the ingot is presented, including the grain size distribution and columnar–equiaxed transition.