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研究生: 拉克希米
Dezfoli, Amir Reza Ansari
論文名稱: 結合有限元素分析法與元胞自動法模擬多晶材料在不同凝固速率下之微結構變化與熱傳導行為
Application of coupled FE and CA method to simulate micro structure and heat transfer of poly crystalline materials solidification with various solidification speeds
指導教授: 黃文星
Hwang, Weng-Sing
共同指導教授: 許文東
Hsu, Wen-Dung
學位類別: 博士
Doctor
系所名稱: 工學院 - 材料科學及工程學系
Department of Materials Science and Engineering
論文出版年: 2017
畢業學年度: 105
語文別: 英文
論文頁數: 131
外文關鍵詞: Cellular Automaton, Finite Element, Directional casting, Silicon Casting, Laser Surface Melting.
相關次數: 點閱:124下載:10
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  • We developed a model in PROCAST base on Cellular Automaton (CA) and Finite Element (FE) methods in order to simulate micro structure of ultra-fast and slow solidification processes. Using this approach, new hopes can be achieved in order to enhance and improve material properties made during solidification processes. The coupled CA-FE model is applied to two important directional solidification processes: silicon ingot casting and laser surface melting which can be considered as ultra-slow and fast solidifications, respectively.
    Here first, finite element (FE) and cellular automaton (CA) models are used in order to predict the microstructure of Poly-Crystalline Silicon (PC-Si) ingots during casting in a directional solidification furnace. During solidification, the 3D-FE model is used to simulate thermal field inside the furnace, while the nucleation and growth of PC-Si are simulated by the modified version of 2D-CA model. In this model both nucleation at silicon-crucible interface and nucleation of equiaxed grains on impurities are modeled. The origin of impurity is considered SiC particles when carbon segregates during the solidification and precipitates as SiC particles if carbon solubility limit is reached. The model is evaluated with experimental data for different parameters, such as: the temperature profile at the top and bottom of the PC-Si, grain size, and the height of solidified silicon during solidification. The effects of the cooling rate and competitive growth on the final microstructure of PC-Si are also investigated. A simulated model is proposed which shows that by changing the density and location of nucleation sites it is possible to achieve more effective control on final PC-Si micro structure.
    We know during the solidification of silicon ingot, the carbon concentration may play a critical role with regard to the final silicon microstructure. If the carbon concentration passes the solubility limit, SiC particles precipitate and it is possible the grain structure changes from columnar to equiaxed grains. Furthermore, carbon atoms are confined inside these equiaxed grains during solidification, which may decrease the carbon concentration inside the liquid silicon, and the equiaxed grains then become columnar again. Therefore, both solidification and carbon concentration will impact each other. A 3D multiscale model is also developed here to simulate the microstructural evolution of Multi-Crystalline Silicon (mc-Si) ingots coupled with the carbon concentration during the casting process. Our microstructural model is based on the simulation of nucleation and crystal growth. Besides modelling the nucleation due to silicon-crucible interaction, our model can successfully represent the occurrence of equiaxed grains observed ahead of a planar faceted interface due to carbon segregation during solidification. In addition, by coupling concentration and crystallization, the transition from columnar to equiaxed growth and equiaxed to columnar growth can be modelled. Several comparisons are made between the mc-Si ingot’s microstructure obtained by our model and the experimental data in order to evaluate our model.
    There are serious questions about the grain structure of metals after laser melting and the ways that it can be controlled. In this regard, in the second approach, the current study explains the grain structure of metals after laser melting using a new model based on combination of 3D finite element (FE) and cellular automaton (CA) models validated by experimental observation. Competitive grain growth, relation between heat flows and grain orientation and the effect of laser scanning speed on final micro structure are discussed with details. Moreover, using the secondary laser heat source (SLHS) as a new approach to control the grain structure during the laser melting is presented.

    Contents Abstract....II List of Tables....VIII List of Figures...IX List of symbols XIII Stefan–Boltzmann constant XVI Chapter 1 Introduction 1 1.1 Relation between material properties and grain size 1 1.2 Solidification of polycrystalline material 2 1.2.1 Nucleation stage 3 1.2.2 Crystal growth stage 4 1.3 Directional Silicon Casting 6 1.4 Laser Melting 10 1.5 Our goal 12 Chapter 2 Coupled Cellular-Automaton and Finite Element method 14 2.1 Thermal modelling 14 2.1.1 Governing Equations 14 2.1.2 Boundary Conditions 15 2.1.3 Radiation Heat Transfer 16 2.2 Finite Element Method 20 2.2.1 Artificial/Pseudo Compressibility 23 2.2.2 Taylor-Galerkin-Stabilization Technique 24 2.2.3 The Choice of Interpolation Functions 25 2.2.4 Backward Euler Time-Approximation scheme 27 2.3 Nucleation models in CA method 28 2.4 Growth models in CA method 31 2.5 Coupling CA and FE models 32 2.5.1 CA Neighborhood 32 2.5.2 Connection between CA and FE models 34 2.6 2D CA-3D FE modelling in Modeling of Poly-Crystalline Silicon Ingot Crystallization during Casting 35 2.6.1 Thermal model 36 2.6.2 Micro structure model 42 2.6.3 CA-FE coupling and procedure 46 2.7 3D CA-FE modelling in Modeling of Poly-Crystalline Silicon Ingot Crystallization during Casting 51 2.7.1 3D CA model 52 2.7.2 Coupling 3D CA with 3D FE 58 2.8 3D CA-FE modelling in Modeling of Grain Structure after Laser Melting 62 2.8.1 Thermal model 62 2.8.2 CA model 64 2.8.3 FE-CA model procedure 67 Chapter 3 Results and discussion 73 3.1 Application of 2D CA- 3D FE modelling in modeling of Poly-Crystalline silicon ingot crystallization during casting 73 3.1.1 Controlling Grain Structure 81 3.2 Application of 3D CA-FE modelling in Modeling of Poly-Crystalline Silicon Ingot Crystallization during Casting 86 3.3 Application of 3D CA-FE modelling in Modeling of Grain Structure after Laser Melting 99 3.3.1 Controlling grain structure during laser melting using secondary laser heat source 110 Chapter 4 Conclusions 116 Chapter 5 Future work 121 BIBLIOGRAPHY 122

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