Segregation in Casting

by

Ali Abdallah Ali

Section Three

Department of metallurgical and materials engineering

Faculty of petroleum and mining engineering
Suez Canal University
Contents

1. Introduction ……………………………3
2. Microsegregation……………………….5
3. Macrosegregation………………………8
4. Dendritic segregation………………….12
5. Gravity segregation……………………14
6. Reference ……………………………...17

2
Abstract

Segregation is one of the defects in the casting

process that have various shapes some are normal and some
are inverse, some occurs on microscopic scale and some on
macroscopic scale, some types result due to difference in
density and some due to difference in temperature, there are
a lot of types and shapes of segregation on which we will
spot some light.

Introduction

Segregation may be defined as any departure from

uniform distribution of the chemical elements in the alloy.
Because of the way in which the solutes in alloys partition
between the solid and the liquid during freezing, it follows
that all castings are segregated to some extent. [1]
During solidification of liquid metals and alloys, crystals
formation takes place. The resulting morphology has
certain characteristics peculiar to cast structures.
Morphology includes both macrostructure and
[3]
microstructure.
Some variation in composition occurs on a microscopic
scale between dendrite arms, known as microsegregation. It
can usually be significantly reduced by a homogenizing
heat treatment because the distance, usually in the range
10-100 µm, over which diffusion has to take place to
redistribute the alloying elements, is sufficiently small. [1]
Macrosegregation cannot be removed. It occurs over
distances ranging from 1 cm to 1 m, and so cannot be

3
removed by diffusion In general, therefore, whatever
macrosegregation occurs has to be lived with. [1]

4
Microsegregation

Intergranular segregation results from accumulation of

rejected solute between the growing crystals and its failure,
due to a physical barrier of solid, to diffuse or mix into the
main body of residual liquid. The final segregation pattern
thus follows the form of the grain or sub-structure. This is
the basis of the typical cored microstructure revealed by
etching contrast, and explains the frequent presence of non-
equilibrium phases in interdendritic regions. [2]
Figure 1 shows the relationship between composition and
dendritic microstructure in carbon chromium steel, in
which the dendrites are depleted and the interdendritic
spaces enriched in chromium. In this case the segregation
ratio

The mechanical properties of a cast alloy are naturally

sensitive to microsegregation, since strength, tensile
ductility; impact properties and fatigue resistance are all
affected by intercrystalline conditions which differ from the
matrix. Apart from functional properties, the
microsegregation of alloying elements and impurities can
affect strength and ductility in the solidus region and can
thus govern susceptibility to hot tearing. [2]

5
 (a)

(b)

Figure 1: Cored microstructure in carbon–chromium steel, showing correlation between dendrite

morphology and composition. (a) Structure, (b) contour map of chromium content as established by
microprobe analysis [2]

6
Where microsegregation results in the appearance of a new
liquid interdendritic phase, there are a number of
consequences that may be important: [1]
1. The presence of a eutectic phase reduces the
problem for fluid flow through the dendrite mesh.
2. The alloy may now be susceptible to hot tearing,
especially if there is only a very few percent of the
liquid phase.
3. A low-melting-point phase may limit the
temperature at which the material can be heat
treated.
4. A low-melting-point phase may limit the
temperature, at which an alloy can be worked, since
it may be weakened, disintegrating during working
because of the presence of liquid in its structure. [1]

7
Macrosegregation

Segregation on a macroscopic scale is produced by

various mechanisms depending upon the mode of freezing.
However, the basic factor is the accumulation of rejected
solute by transport over relatively long distances through
the casting. In the simplest case, usually termed normal
segregation, the final parts of the casting to freeze contain
high concentrations of solute elements, whilst the term
inverse segregation is used to describe the opposite
condition. [2]
Macrosegregation occurs during solidification due to
relative movement or flow of segregated liquid and solid.
There are numerous causes of fluid flow and solid
movement in casting processes. One reason for this
movement of segregated liquid may be density differences
of the metal due to temperature or variations in
composition. [4]
The hot liquid metal becomes cooler close to the chill
surfaces and its density increase causing downward
movement. Liquid being enriched by rejected solutes with
higher density compared to the bulk composition will flow
downward and the opposite will happen when low mass
elements enrich the liquid. [4]
During ingot casting, the most common macrosegregations
are the positive, negative and channel segregations.
Positive segregation means that the concentration of
alloying element exceeds the average bulk concentration.
egative segregation is instead a local lack of alloying
element. [4]

8
The positive segregation is often found at the top and is the
result of segregated liquid flow toward the top and the
negative zone with more pure material at the bottom of the
ingot is explained by sedimentation of equiaxed crystals
formed in the bulk liquid. [4]
Figure 2 shows a plot over the segregation ratio, C/C0 of
carbon and sulphur in the rectangular ingot. As to be
expected the macrosegregations follow the well known
behavior. [4]
In the figure, the concentration along three horizontal lines,
representing three height levels, from surface to centre are
shown to the left, the centerline segregation is shown in the
middle and the position of each drill sample are shown to
the right. [4]
A sulphur print of the corresponding surface is shown in
figure 3. In this ingot, an increase of the segregation ratio is
seen toward the top. At the bottom of the ingot a somewhat
increasing negative segregation is found. [4]

9
Figure 2: Segregation ratio of S and C. Sample location is shown in the right figure.

10
Figure 3: Sulphur print of vertical cross-section of rectangular ingot.

11
Dendritic segregation

It is Inhomogeneous distribution of alloying elements

through the arms of dendrites. [5]
Figure 4 shows how microsegregation can lead to a form of
macrosegregatio. [1]
As freezing occurs in the dendrites, the general flow of
liquid carries the progressively concentrating segregate
towards the roots of the dendrites. [1]

Figure 4: Normal dendritic segregation (usually misleadingly called inverse segregation) arising as a result
of the combined actions of solute rejection and shrinkage during solidification in a temperature gradient.

For the case of dendritic growth against the wall of the

mould, however, the temperature gradient will ensure that

12
all the flow is in the direction towards the wall,
concentrating the segregation here. Thus the presence of a
temperature gradient is necessary for a significant build-up
of segregation. [1]
Dendritic segregation is observable but is not normally
severe in sand castings because the relatively low
temperature gradients allow freezing to occur rather evenly
over the cross-section of the casting; little directional
freezing exists to concentrate segregates in the direction of
heat flow.
It will by now be clear that this type of segregation is in
fact the usual type of segregation to be expected in
dendritic solidification. [1]

13
Gravity segregation

Gravity plays an important role in the formation of

segregation. Settling or flotation of liquid or solid phases
having a different composition, and therefore a different
density than the bulk liquid, will produce gravity
segregation. [6]
Gravity segregation is mainly encountered in heavy
sections, where solid phases can be suspended in the liquid
for some time. [2]
Positive segregation have more solute than the average for
the ingot and it have two types the A segregates and the V
segregates
The 'A' type segregates in a steel ingot are formed in this
way (Figure 5) also called Freckles refers to the streaks
oriented almost vertically in an A-pattern at the upper and
outer regions of the ingots and it is a positive segregation.[6]
The 'V' type segregates also called channel centerline and it
is located in the center of the ingot. [6]
They are characterized by a sharply delineated edge on the
opposite side to that shown by the A segregates. [1]
It seems that they form at a late stage in the freezing of the
ingot, when the segregated pool of liquid floating at the top
of the ingot is drawn downwards to feed the solidification
shrinkage in the centre and lower parts of the ingot. [1]

14
Figure 5: Development of segregation in a killed steel ingot (a) during solidification and (b) in the final ingot.

15
On sectioning the ingot transversely, and etching to reveal
the pattern of segregation, the A and V segregates appear as
a fairly even distribution of clearly defined spots, having a
diameter in the range of 2-10 mm. probably depending on
the size and shape of the ingot, they may be concentrated at
mid-radial to central positions in zones, or evenly spread. [1]
Negative segregation is distributed in a cone at the base of
the ingot. [6]
Negative segregation has less solute than the average for
the ingot and it increasing by increasing the width of the
ingot. [1]
Although few ingots are cast in modern steelworks, large
steel castings continue to be made in steel foundries. Such
castings are characterized by the presence of channel
segregates, in turn causing extensive and troublesome
macrosegregation. Channel segregates can be controlled
by:
1. Decreasing the time available for their formation by
increasing the rate of solidification.
2. Adjusting the chemical composition of the alloy to
give a solute-rich liquid that has more nearly neutral
buoyancy at the temperature within the freezing zone.
[1]

16
Reference

1. Castings 2nd edition by John Campbell OBE FREng

Professor of Casting Technology, University of
Birmingham, UK.
2. Foundry Technology 2nd edition by Peter Beeley
BMet, PhD, DMet, CEng, FIM, FIBF Life Fellow and
formerly Senior Lecturer in Metallurgy, University of
Leeds.
3. Segregation in cast products by A GHOSH
Department of Materials and Metallurgical
Engineering, Indian Institute of Technology, Kanpur
208 016, India.
4. Slag inclusion formation during solidification of Steel
alloys and in cast iron by Sofia Adolfi Licentiate
Thesis Materials Processing Department of Material
Science and Engineering School of Industrial
Engineering and Management Royal Institute of
Technology SE-10044 Stockholm, Sweden.
5. http://www.engnetglobal.com/tips/glossary.aspx?word
=Dendritic+Segregation
6. Science and Engineering of Casting Solidification By
Doru Michael Stefanescu

17