Sensitivity of mesh spacing on simulating macrosegregation during directional solidification of a superalloy

The sensitivity of mesh spacing on simulations of macrosegregation, particularly ‘freckles’, during vertical directional solidification of a superalloy in a rectangular mold was systematically analyzed to achieve accurate predictions in finite element calculations. It was observed that a coarser mesh spacing in the x‐direction horizontal tends to minimize the simulated macrosegregation, whereas a coarser mesh spacing in the y‐direction vertical artificially tends to make the system appear to have more macrosegregation. When solidification conditions either lead to a well‐established freckling case or to a well‐established non‐freckling case, the simulated results are not sensitive to the mesh spacing provided the elements are no larger than about 2d₁ by 2 D/V and 3d₁ by 4 D/V respectively, where d₁ is the primary dendrite arm spacing, D is the diffusivity of the alloy solute with the smallest diffusivity in the liquid, and V is the growth rate. However, when solidification conditions are very close to the transition between freckling and no freckling, the simulated results are sensitive to the mesh spacing, especially in the y‐direction. Based on the mesh sensitivity analysis from the two‐dimensional simulations of rectangular castings of René N5, the mesh with element dimensions no larger than 2d₁ in the x‐direction and 1.5 D/V in the y‐direction are recommended as the most stringent element size. Copyright © 2001 John Wiley & Sons, Ltd.