Numerical simulation of flow field and temperature field during melt impingement additive solidification process of 7050 aluminum alloy under the influence of forced convection

The solidification behavior of 7050 aluminum alloy during the melt impingement additive solidification (MIAS) process is a critical factor influencing microstructural development and the mitigation of defects such as solute segregation and cracking. This study utilized numerical simulations, validated by experimental data, to examine the effects of forced convection on flow dynamics and temperature fields during solidification. The results demonstrate that melt flow patterns, particularly the formation of counter-rotating vortices, significantly impact heat transfer and solute distribution. Temperature profiles exhibit high sensitivity to melt impingement velocity, with increased velocity resulting in a reduction of central temperature. Additionally, higher impingement velocities reduce the thickness of the mushy zone while expanding the heat-affected zone, thereby promoting interface instability. Melt convection induced by MIAS predominantly governs microstructural evolution and grain refinement. These findings advance the understanding of convective and thermal interactions during alloy solidification and provide a theoretical basis for optimizing MIAS parameters to fabricate high-integrity alloys with tailored microstructures and properties.