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a b s t r a c tFor almost half a century the catastrophic failure of direct chill (DC) cast high strength aluminum alloys has been challenging the production of sound ingots. To overcome this problem, a criterion is required that can assist the researchers in predicting the critical conditions which facilitate the catastrophic failure of the ingots. This could be achieved at first glance by application of computer simulations to assess the level and distribution of residual thermal stresses. However, the simulation results are only able to show the critical locations and conditions where and when high stresses may appear in the ingots. The prediction of critical void/crack size requires simultaneous application of fracture mechanics. In this paper, we present the thermo-mechanical simulation results that indicate the critical crack size distribution in several DCcast billets cast at various casting conditions. The simulation results were validated upon experimental DC-casting trials and revealed that the existence of voids/cracks with a considerable size is required for cold cracking to occur.

Coarsening within the mushy zone during continuous directional solidification experiments was studied on an Al-30 wt pct Cu alloy. High brilliance synchrotron X-radiation microscopy allowed images to be taken in-situ during solidification. Transient conditions were present during directional solidification. Under these conditions, solute-rich settling liquid flow affects the dendritic array and thus coarsening. Coarsening was studied by following the secondary dendrite arm spacing (SDAS) of a developing dendrite at different local solidification times according to the mush depth and instant interface velocity. Solute enrichment and liquid flow cause deceleration and acceleration of the solidification front, which in turn influences both the mush depth and local growth and coarsening due to variations in solutal gradients and thus local undercooling. In addition, spacing between neighboring dendrites (i.e., primary dendrite arm spacing), which determines permeability within the mushy zone, affects the development of high-order branches.

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