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Diffusive and phase change instabilities in a ternary mushy layer

Published online by Cambridge University Press:  12 November 2014

Peter Guba
Affiliation:
Department of Applied Mathematics and Statistics, Faculty of Mathematics, Physics and Informatics, Comenius University, 842 48 Bratislava 4, Slovakia
Daniel M. Anderson*
Affiliation:
Department of Mathematical Sciences, George Mason University, Fairfax, VA 22030, USAApplied and Computational Mathematics Division, National Institute of Standards and Technology, Gaithersburg, MD 20899-8910, USA
*
†Email address for correspondence: danders1@gmu.edu
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Abstract

We analyse the stability of a mushy layer during the directional solidification of a ternary alloy. Our model includes diffusive and convective transport of heat and solutes, coupled by an equilibrium thermodynamic constraint of the ternary phase diagram. The model contains phase change effects due to latent-heat release, solute rejection and background solidification. We identify novel convective instabilities, both direct and oscillatory, which are present under statically stable conditions. We examine these instabilities asymptotically by simplifying to a thin mushy layer with small growth rates. We also discuss numerical results for the full problem, confirming the asymptotic predictions and providing the stability characteristics outside the small-growth-rate approximation. A physical explanation for these instabilities in terms of parcel arguments is proposed, indicating that the instability mechanisms generally involve different rates of solute diffusion, different rates of solute rejection and different background solute distributions induced by the initial alloy composition.

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Papers
Copyright
© 2014 Cambridge University Press 
Figure 0

Figure 1.A schematic of the ternary phase diagram. The three corners of a triangular base of the phase diagram correspond to the pure components 1, 2 and 3 of the ternary alloy. The liquidus surface and the solidus surface associated with the corner 3 are illustrated. A typical solidification path and its projection onto the base of the diagram are also depicted, indicating the phase trajectory of ternary melt as it descends along the liquidus surface. The solidification path corresponds to the formation of a primary mushy layer made up of dendrites of a component-3-rich solid phase surrounded by the residual liquid. In an ideal primary mushy layer, both the liquidus and solidus surfaces are taken to be planar.

Figure 1

Figure 2.Schematic representation of the neutral-stability curves (solid) and the regions of instability (shaded) for direct modes in the four scenarios: (a) ${\it\Omega}_{1}+\hat{{\it\Omega}}_{1}>0$, $c_{1}>0$, $d_{1}<0$; (b) ${\it\Omega}_{1}+\hat{{\it\Omega}}_{1}>0$, $c_{1}<0$, $d_{1}>0$; (c) ${\it\Omega}_{1}+\hat{{\it\Omega}}_{1}<0$, $c_{1}>0$, $d_{1}<0$; (d) ${\it\Omega}_{1}+\hat{{\it\Omega}}_{1}<0$, $c_{1}<0$, $d_{1}>0$. The stability diagrams for case (a) are qualitatively related to those for case (d) by the sign change $\overline{Ra}_{1}\mapsto -\overline{Ra}_{1}$, ${\it\Omega}_{1}+\hat{{\it\Omega}}_{1}\mapsto -({\it\Omega}_{1}+\hat{{\it\Omega}}_{1})$, $c_{1}\mapsto -c_{1}$ and $d_{1}\mapsto -d_{1}$; similarly for cases (b) and (c). It should be noted that $c_{1}$ and $d_{1}$ have opposite signs in each case, so that overstability does not arise. In each plot, the stability results from the small-${\it\delta}$ theory are strictly valid locally in a region of width $O({\it\delta})$ centred on the neutral-stability boundary, as indicated in (b).

Figure 2

Figure 3.Frequency ${\it\sigma}_{I}^{1}$ as a function of wavenumber $k$ for $n=1$ and (a) $Q_{1}={\textstyle \frac{1}{8}}$, (b) $Q_{1}={\textstyle \frac{1}{4}}$, (c) $Q_{1}\approx 49.867$ and (d) $Q_{1}=100$. In each case, there is a family of disjoint solution branches, asymptoting to ${\it\sigma}_{I}^{1}=(2l+1){\it\pi}$ as $k\rightarrow \infty$ (dashed), where $l$ is a positive integer. Many more branches occur for increasing $k$; only the first three, labelled 1–3, are shown. The scales in each plot are the same to allow the effect of $Q_{1}$ to be seen more easily. For $Q_{1}<{\textstyle \frac{1}{4}}$, as in (a), there is a long-wavelength cutoff along the mode-1 branch. In (c), there is a breakup of the mode-2 branch, resulting in a decoupled pair of branches, as apparent in (d). Similar behaviour is exhibited by all the higher solution branches.

Figure 3

Figure 4.Schematic representation of the neutral-stability curves for the direct mode (solid), the oscillatory modes (dashed), the transition boundary separating the growing direct modes from the growing oscillatory modes (dotted), and the regions of instability (shaded) in the four scenarios: (a) ${\it\Omega}_{1}+\hat{{\it\Omega}}_{1}>0$, $c_{1}>0$, $d_{1}>0$; (b) ${\it\Omega}_{1}+\hat{{\it\Omega}}_{1}>0$, $c_{1}<0$, $d_{1}<0$; (c) ${\it\Omega}_{1}+\hat{{\it\Omega}}_{1}<0$, $c_{1}>0$, $d_{1}>0$; (d) ${\it\Omega}_{1}+\hat{{\it\Omega}}_{1}<0$, $c_{1}<0$, $d_{1}<0$. The stability diagrams for case (a) are qualitatively related to those for case (d) by the sign change $\overline{Ra}_{1}\mapsto -\overline{Ra}_{1}$, ${\it\Omega}_{1}+\hat{{\it\Omega}}_{1}\mapsto -({\it\Omega}_{1}+\hat{{\it\Omega}}_{1})$, $c_{1}\mapsto -c_{1}$ and $d_{1}\mapsto -d_{1}$; similarly for cases (b) and (c). It should be noted that $c_{1}$ and $d_{1}$ have the same sign in each case, so that oscillatory modes are present for sufficiently large wavenumbers. Only the first three oscillatory branches are shown. As in figure 2, the results are valid only in a local sense (i.e. within an $O({\it\delta})$ neighbourhood of the neutral-stability boundary).

Figure 4

Figure 5.Growth rate ${\it\sigma}_{R}^{1}$ as a function of Rayleigh number $\overline{Ra}_{1}$ (shown in the ${\it\sigma}_{R}^{1}$ versus $\overline{Ra}_{1}$ plane) for fixed $k$ and $n=1$. Cases (a–d) correspond to the neutral-stability diagrams portrayed in figures 4(a–d), respectively, with the plots on the left (right) representing cross-sections at $k ($k>k_{\mathit{cutoff}}$); $k_{\mathit{cutoff}}$ is the lowest oscillatory mode wavenumber cutoff as identified in the analysis of § 4.2. In each plot, the solid (dashed) curve corresponds to the direct (oscillatory) solution branch; only the first two oscillatory modes are indicated.

Figure 5

Figure 6.Sketches of typical neutral-stability curves for the direct mode (solid), the oscillatory modes (dashed) and the transition boundary separating the growing direct modes from the growing oscillatory modes (dotted) in the $(k,\overline{Ra}_{1})$-plane for representative cases (a) $0, (b) $Q_{1}={\textstyle \frac{1}{4}}$, (c) $Q_{1}\approx 49.867$ and (d) $49.867. The oscillatory branches are labelled as in figure 3. Each sketch applies to the case $\overline{Ra}=\overline{Ra}_{2}=0$ (case 1), and ${\it\Omega}_{1}+\hat{{\it\Omega}}_{1}<0$, $c_{1}<0$ and $d_{1}<0$ (scenario d in figure 4). The system is linearly unstable in the shaded region. This region divides, as in (a), into three domains, marked I–III, in which a pair of growing oscillatory modes exists (I), two growing direct modes exist (II) and a single growing direct mode exists (III). As $Q_{1}$ increases, the point at which the mode-1 branch terminates on the direct branch as well as the noses of the higher oscillatory branches (modes 2 and 3) move to smaller wavenumbers (cf. figure 3). In (b) the mode-1 branch terminates on the direct branch at $k=0$, while in (c) and (d) there is no such termination. In (c) the mode-2 branch splits at $k=0$ to form a decoupled pair of oscillatory branches, as seen in (d).

Figure 6

Figure 7.Regime diagrams. The regions of different convective scenarios, as identified in figures 2 and 4, are indicated. Plots (a) and (c) show the results in the $(\mathscr{C}_{1},\mathscr{C}_{2})$-plane, with equal Lewis numbers ($\mathit{Le}_{1}=\mathit{Le}_{2}=5$) in (a) and unequal ones ($\mathit{Le}_{1}=5$, $\mathit{Le}_{2}=10$) in (c). Plots (b) and (d) show the results in the $(\mathit{Le}_{1},\mathit{Le}_{2})$-plane, with equal compositional ratios ($\mathscr{C}_{1}=\mathscr{C}_{2}\equiv \mathscr{C}$) in (b) and unequal ones ($\mathscr{C}_{1}=-5$, $\mathscr{C}_{2}=-1$) in (d). The results in (b) are independent of the value of $\mathscr{C}$. The remaining parameters are fixed at $\bar{S}=0$, $m_{1}=m_{2}={\textstyle \frac{1}{2}}$ and ${\it\phi}_{0}=0$. The neutral-stability curves, validated numerically, at the points marked ○ and ● in (a) are shown in figures 10(a) and (b).

Figure 7

Table 1.Classification of convective scenarios for case 1. In scenarios (c) and (d), an instability arises despite an arguably statically stable density stratification. In scenarios (b) and (d), buoyancy forces oppose an instability: if $\mathit{Ra}_{1}$ is decreased from the neutral value, the growth rate ${\it\sigma}_{R}$ of perturbations decreases, in contrast to normal expectations. It should be noted that the position of the neutral-stability boundaries is controlled by the sign of ${\it\Omega}_{1}+\hat{{\it\Omega}}_{1}$, while the response of unstable modes to stratification is controlled by the sign of $c_{1}$. The presence of an oscillatory instability in each scenario is controlled by the sign of $d_{1}$.

Figure 8

Figure 8.A mechanism of a direct instability of stably stratified ternary mushy layers with no solid solutions (see § 5.2). The solid line corresponds to the solidification path in the $(C_{1}^{\ast },C_{2}^{\ast })$-plane. The dotted line corresponds to the tie line joining the origin and the bottom of the mush. The dashed lines indicate the isotherms. The density decreases from bottom to top, implying a statically stable stratification. When a parcel initially at point P, here chosen to correspond to the mush bottom, is displaced upwards to a QR isotherm, a dissolution of the solid dendrites forces the parcel to adjust its net composition to that of point R whose solute 1 content, and hence density, is less than that of point Q.

Figure 9

Figure 9.Neutral-stability results as a function of the compositional ratio $\mathscr{C}_{2}$, at fixed $k={\it\pi}$. The symbols are results from the full numerical model (○ for a direct mode, $\times$ for an oscillatory mode). The curves are the small-${\it\delta}$ asymptotic results given by (4.7) for a direct mode (solid), and (4.8) and (4.9) for an oscillatory mode (dashed). The direct mode exhibits pole-like behaviour near ${\it\Omega}_{1}+\hat{{\it\Omega}}_{1}=0$, as captured both asymptotically and numerically. The asymptotics captures the low-frequency oscillatory behaviour near the point $Q_{1}={\textstyle \frac{1}{8}}$ at which the oscillatory mode branches off the direct mode (see the insets), but fails to show a smooth transition near $c_{1}=0$ to the higher-frequency modes evidenced numerically. It should be noted that in the upper inset only the most dangerous portion of the neutral-stability boundary is shown for clarity. The remaining parameters are fixed at $\mathscr{C}_{1}=-5$, $\bar{S}=0$, $m_{1}=m_{2}={\textstyle \frac{1}{2}}$, ${\it\phi}_{0}=0$, $\mathit{Le}_{1}=\mathit{Le}_{2}=5$, $k_{1}=k_{2}=0$, $K_{1}=0$, $\overline{Ra}=\overline{Ra}_{2}=0$, ${\it\delta}={\textstyle \frac{1}{10}}$ and $N_{P}=2^{5}$.

Figure 10

Figure 10.Neutral-stability curves $\overline{Ra}_{1}$ versus $k$, as calculated from the full numerical model (○ for a direct mode, $\times$ for an oscillatory mode) and the asymptotic model (solid curve for a direct mode) for (a) $\mathscr{C}_{2}=-4$ and (b) $\mathscr{C}_{2}=-1$. In (a) the asymptotics predicts the scenario identified in figure 2(b), while in (b) the scenario of figure 2(d) is predicted. The asymptotic results are in excellent agreement with the numerical results, although an oscillatory instability with an $O(1)$ frequency for $\overline{Ra}_{1}<0$ is not captured by the asymptotics. Other parameter values are identical to figure 9.