Coupled Temperature–Flow Field and Microstructure Numerical Simulation of the Solidification Process for Cu-3Ti-0.2Fe Alloy

This work investigates the time-dependent changes in temperature, flow, and solidification microstructure under various cooling conditions. The mechanism of the effects of different pouring temperatures on the morphology and evolution of the solidification microstructure is explored. During gradual cooling, the temperature distribution remained consistent and the solid-liquid interface extended to its furthest extent. In contrast, water cooling generated the most pronounced temperature gradient at the solidification front, which was conducive to the development of columnar grains. Specifically, the maximum solidification rates at the center of the casting under the water-cooled copper mold, copper mold, and ceramic mold conditions were 2.71 mm/s, 1.45 mm/s, and 0.95 mm/s, respectively, with water cooling achieving the fastest rate. In the early stages of solidification, the flow velocity at the casting center was relatively high, and during slow cooling, the molten material tended to flow toward the surface. When air cooling was applied, the molten material at the center migrated outward, while under water cooling, the fluid moved in an upward direction. At a heat transfer coefficient of 100 W/(m²·K), the alloy primarily formed equiaxed grains; however, at 5000 W/(m²·K), the proportion of columnar grains increased significantly, and the average grain area expanded from 3.664 × 10^-6 m² to 4.441 × 10^-6 m². Additionally, as the pouring temperature increased from 1100 °C to 1200 °C, the number of grains decreased, while the average radius grew from 1.665 × 10^-3 m to 1.820 × 10^-3 m, resulting in a reduced fraction of equiaxed grains. This study provides valuable theoretical insights for optimizing the solidification process of this particular alloy.