Microstructure Evolution of Cu-Ag Alloy During Directional Solidification Under a Transverse Magnetic Field

Magnetic field-assisted casting technologies have received extensive research attention. Applying a transverse magnetic field during directional solidification offers an effective, non-contact approach to control the microstructure of Cu-Ag alloys by modulating melt convection. However, a comprehensive quantitative understanding of its mesoscopic influence on solute-driven dendritic growth and the columnar-to-equiaxed transition (CET) is still lacking. In this study, a coupled phase-field and lattice Boltzmann (PF-LBM) model is employed to systematically investigate the effect of a transverse magnetic field on columnar dendrite evolution and CET kinetics during the directional solidification of Cu-Ag alloys. Results show that the field-induced Lorentz force disrupts the symmetry of the solute field ahead of the dendrite tip, driving tilted dendritic growth that intensifies with decreasing initial primary spacing. During the CET process, the magnetic field overrides the randomness of grain nucleation by selecting specific crystallographic orientations. More importantly, it effectively mitigates the thermodynamic suppression of equiaxed nucleation typically caused by high temperature gradients. Furthermore, an increased magnetic field intensity not only accelerates the occurrence of CET but also significantly diminishes the inhibitory effect of high nucleation barriers on the transition. Ultimately, this work provides fundamental insights into external field-induced orientation selection mechanisms of as-cast grains and establishes a theoretical framework for quantitatively controlling texture evolution during the subsequent processing of high-flexure Cu-Ag alloys.