Thermodynamic and solidification modeling coupled with experimental investigation of the multicomponent aluminum alloys

In order to obtain a thermodynamic description for the Al-Cu-Mg-Si quaternary system, three constituent binary systems, Al-Si, Cu-Si and Mg-Si, are first modeled based on the available experimental data, and the thermodynamic models used to describe the phases in the binary systems are presented. The calculated binary phase diagrams and the thermodynamic properties are in good agreement with the experimental data. Three constituent ternary systems, Al-Cu-Si, Al-Mg-Si and Cu-Mg-Si, are then modeled based on experimental data available in the literature. A thermodynamic description of the Al-Cu-Mg-Si system has been developed based on the established descriptions of its constituent binaries and ternaries as well as using data relating to the quaternary intermetallic compound Q-Al₅Cu₂Mg₈Si₆. The calculated quaternary phase diagrams, including invariant equilibria, isopleths and isotherms are in accord with the experimental data available in the literature. The phase equilibria and thermodynamic properties of the Al-Cu-Mg-Si system can now be calculated from this thermodynamic description at any temperature and composition.; A numerical microscopic model has been developed in the present study for the prediction of the microstructure and microsegregation in multicomponent alloys during dendritic solidification. This microscopic model is directly coupled with multicomponent phase diagram calculations using a user-friendly and robust phase diagram calculation engine-PANENGINE. Solid back diffusion, thermodynamic correction of the interface concentrations, undercooling and dendrite arm coarsening effects are included in this model. The experimentally measured or calculated cooling curves are input into the model to carry out the microsegregation calculations.; To validate the microscopic model and the Al-Cu-Mg-Si thermodynamic description, microstructures and microsegregations in a Al-4.5wt%Cu binary alloy, as well as Al-4.5wt%Cu-1wt%Si-0.5wt%Mg and Al-6.27wt%Cu-0.22wt%Si-0.19wt%Mg quaternary alloys, have been experimentally investigated using directional solidification and electron probe microanalysis (EPMA). Calculated results from this model are in accord with the experimental data.; Finally, the micromodel and the 12-component Al thermodynamic database were used to predict the microsegregation and microstructure in two commercial alloys (10-component W319 and 11-component 7050). Predicted results are in very good agreement with the experimental data. The verified aluminum database and micromodel can be used with confidence in the aluminum industry.