Cellular automaton simulation and experimental validation of eutectic transformation during solidification of Al-Si alloys

The morphology of eutectic silicon in solidification microstructure is critical to the performance of Al-Si-based alloys. Simulating eutectic Si phase formation has been a challenge in ICME (integrated computational materials engineering) based design and manufacturing of solidification products of Al-Si-based alloys. In this study, our previous three-dimensional (3-D) cellular automaton (CA) model for α-Al dendritic growth was extended to include eutectic (α-Al + Si) transformation in multi-dendrite domains, providing a complete solidification simulation of critically important Al-Si based alloys. The quantitative results of the Si phase in the eutectic microstructure were experimentally validated using scanning electron microscopy and deep etching techniques. The simulation results show a good agreement with the experimental observations and calculations by the Scheil model and lever rule. This 3-D CA model is useful for predicting and optimizing the solidification microstructure including eutectic transformation during solidification processing such as casting, potentially welding, and additive manufacturing.