MATHEMATICAL COMPUTER MODELLING Mathematical
PERGAMON
and Computer
Modelling
36 (2002)
147-156 www.elsevier.com/locate/mcm
Modelling and Asymptotic Analysis of Particle-Interface Interaction L. HADJI Mathematics
Department,
The University AL 35487-0350
[email protected]
of Alabama
Tuscaloosa,
(Received September 2000; accepted February 2002) Abstract-An asymptotic study of the interaction between a foreign particle and a solidifying interface is undertaken. The analysis focuses primarily on the influence of the disjoining pressure on particle pushing or engulfment. The analysis considers only thermal effects in a pure substance in which a neutrally buoyant spherical particle, whose thermal conductivity is equal to that of the melt, is positioned near the solid-liquid interface. The interface equilibrium temperature includes the undercooling effects due to both the front curvature (the Gibbs-Thomson effect) and the long-range intermolecular forces (nonretarded vanderwaals interactions) in the thin film behind the particle. A uniformly valid asymptotic representation for the front shape is derived and used to infer the gap width separating the particle from the solid front. The latter is utilized to calculate the growth rate that results from a balance of the van der Waals and Stokes forces. An attempt is also made at deriving an expression for the critical velocity for continuous pushing from the balance of forces. @ 2002 Elsevier Science Ltd. All rights reserved.
Keywords-Solidification, Materials processing flows, Particulate-reinforced posites, Solid-liquid transitions, Stokesian dynamics.
metal-based
com-
1. INTRODUCTION The interaction
between
an advancing
solid-liquid
interface
and solid particles
is a phenomenon
which occurs in several industrial and natural processes. This is the case, for instance, of the growth of Y123 superconductors [l], the freezing of water in the presence of soil particles during the formation of frost heave in the winter season [2], the cryopreservation of biological cell suspensions [3], and the solidification processing of particulate reinforced metal matrix composites [4]. It is well known that when a particle interacts with a solidifying interface, it is either pushed or engulfed in the solid. Several experimental and theoretical studies have been performed for the purpose of quantifying the pushing/engulfment phenomena [5-111. These studies have demonstrated the existence of a critical value of the growth rate which separates pushing from engulfment. The dependence of this critical velocity on the physical and processing parameters has not been fully resolved and remains an intensive area of research. This paper considers the influence of the disjoining pressure on particle’s engulfment. We proceed by allowing one neutrally buoyant and insoluble spherical particle to be near enough This research was supported by a grant from the National Science Foundation (DMS-9700380). 0895-7177/02/$ - see front matter PII: SO895-7177(02)00111-5
@ 2002 Elsevier
Science
Ltd. All rights reserved.
Typeset
by &S-‘&X
148
L. HADJI
the interface that the gap between the planar front and the nearest point on the sphere is much smaller than the radius of the particle. This situation arises when the particle is in near-contact with the interface. Our model consists of the equations governing the solidification of a pure substance
in the presence of an inert spherical particle in the melt ahead to the interface.
The
model accounts for (i) thermal diffusion in the melt, solid, and particle, (ii) conservation of energy at the solid-liquid interface, and (iii) the modification of the local melting temperature ing pressure effects.
due to the Gibbs-Thomson
and disjoin-
The flow field is uncoupled from the thermal field due to the small value of the particle’s Reynolds number [12,13].
Thus, the equations for the conservation
of momentum in the melt, as well as
the convection term in the energy equation may be ignored in the formulation (to the order at which the present calculations are carried out of course). The determination of the profile of the solid-liquid interface,
being an equilibrium situation,
is not affected by fluid motion.
The
effect of the fluid flow does appear, however, as additional terms in the boundary condition for the interface temperature (see [14]). These two terms owe their existence to the hydrodynamic pressure and the disjoining pressure in the film of melt between the particle and the solid front. The former is much smaller in magnitude than the latter and is not included in the analysis (see [14]). Because our concern here is with the effect of the disjoining pressure on the front morphology, the appropriate length scale is selected by equating the pressure variations induced by the particle’s presence to those due to the front curvature. A nondimensionalization procedure is then undertaken to reduce the large number of physical and processing variables to only a few dimensionless numbers. Two of these groupings stand out in the analysis, namely, a disjoining parameter fl and a front curvature parameter I’. Using a small-gap asymptotic analysis [15,16], we derive a uniformly valid expression for the front shape from which we derive an expression for gap thickness as function of the relevant physical and processing parameters. Then the forces acting on the displaced particle are investigated. It is these forces that will determine the pushing or capture of the particle by the moving solidifying interface.
These forces, that depend on the
gap separation, consist of the viscous drag force, which opposes the movement of the particle, and the van der Waals force which pushes the particle away from the interface (assuming a positive disjoining pressure). The application of the steady-state force equilibrium condition then yields an expression for the growth rate.
2. MATHEMATICAL
MODEL
We consider the directional solidification of a pure substance in such a way that the solidifying front is moving vertically
upward with velocity V. An inert and neutrally buoyant spherical particle is located at a distance h, from the planar solid-liquid interface. See Figure 1 for a schematic diagram. The system is completely described by the heat conduction equations in the liquid, solid, and particle. In addition, the equation for the mass conservation is implicitly accounted for. The latter is not shown in the formulation given that its effect enters the problem only through the boundary condition, i.e., it gives rise to an extra undercooling term in the condition for the local equilibrium temperature (see [10,14]). The influence of this term on the local melting point is found to be much smaller than the other undercoolings and, therefore, is dropped from the analysis. We consider an axisymmetric geometry with a moving cylindrical coordinate system which immobilizes the solid-liquid interface. With the vertical coordinate denoted by Z* and the radial coordinate, which is taken along the planar solid-liquid interface, by r*, the governing equations for the dimensional variables (denoted by *) are dT* --v&$ at*
(r*g)
-t-K-
@T*
az*2 ’
Modelling
and Asymptotic
Analysis
149
Liquid phase Particle
1”
h;
ace
aterf
Solid phase Figure 1. Sketch of the geometry of the problem. A particle of radius a is positioned at a distance h, from the planar solid-liquid interface. The deformable interface moves upward with a prescribed velocity V.
dT.9’ -at*
i a aTs* a2T, * = KS-r*+r;sr+ dr* ( dr* > a2e2 ’ aTp dT’ a2T, i a _-_V__LEK _+ QdZ*23 at* az* ‘r* dr*
where
vaTs’ a2
T’ and ts are the temperature
subscripts
S and p pertain
diffusion
boundary,
T* = T;
coefficient
in the solid phase and particle,
z* = h’ + a - dm and of the heat flux yield
At the particle-liquid temperature
and the thermal
to properties
and
in the liquid, the continuity
of the
n = 0,
k and k, are the thermal conductivities of the melt and denotes the normal to the particle-melt boundary that is pointing
where
and the
respectively.
E B*(r*),
V (kT* - kpTi)
(2)
(4)
the particle, respectively, n into the liquid and V is the
gradient vector. Furthermore, we allow Ti to have some prescribed value To* at some elevation z* = d*. If we neglect the kinetic and hydrodynamic effects, the solid-liquid interface equilibrium temperature
is given by [lo] T = Ts = T,,, i- AT,,,,
where AT,,,,
is the curvature
undercooling
interface
energy,
(5)
given by the Gibbs-Thomson
ATcur, = g [ where Q is the crystal-melt
+ AT,,,
AH,
f
formula
6
(6)
1
is the molar entropy
of fusion,
R denotes
the
molar volume of the liquid phase (taken to be the same as the molar volume in the solid phase) and K is the mean curvature of the interface (positive when the center of curvature is in the liquid phase). The undercooling term AT,, represents the change in the melting temperature due to the vander
Waals forces in the film separating
the particle
from the interface
and is given
by 1141
ATdp = [&][67rlc*)] ’
(7)
where g(r*) is the gap thickness, i.e., the depth of the melt film that is sandwiched between the particle and the solid-liquid interface and where A is the Hamaker constant. The Hamaker constant is taken here to be positive when the disjoining pressure decreases as g(r*) decreases. Far away from the interface, the temperature gradient in the solid phase is maintained at G;. When the particle enters the near-contact region, it induces pressure variations in the melt film. These pressure changes owe their existence to the disjoining pressure PDp, and the pressure
150
L. HADJI
that is associated spherical particle
with the front curvature of radius a, the pressure
while the disjoining
pressure
Since we are concerned by setting
surface
-A
DP=
with the interface
energy
]A(/67re3 = 2a/a.
For a
is given by P
of interfacial
as a result of the Gibbs-Thomson effect PGT, variation induced by the front deformation is
6rg3(r*)
’
deformations
and the disjoining
pressure,
that
are induced
the relevant
by the coupled
length
effects
scale is determined
We obtain
al-4
e =
1’3
(10)
127ra L-1
In the nondimensionalization of the equations and boundary conditions, we use e as lengthscale in the vertical direction and the radius of the particle, a, as a lengthscale in the horizontal direction, C2/K as a scale for time and the fusion temperature of the pure substance of temperature. The following equations in dimensionless form are obtained:
T, as a scale
(11) (12) (13) where E = e/a and v = N/K. The corresponding boundary conditions in dimensionless form are discussed in the following. Since we are focusing on the liquid region that is sandwiched between the particle and the solidliquid
interface,
the upper
boundary
for the liquid region is given by (see [16]) cz=?+l-&7,
(14)
where h, is the distance between the planar interface and the nearest point on the particle, i.e., the minimum clearance between the particle and the solid front prior to the deformation of the interface (see Figure 1). The particle is assumed to be in the near-contact region so that h, << a. We now assume that h, = O(e) and so h,/a = EH where H = O(1). At this upper boundary, which in dimensionless form is denoted the temperature imply V(T - uTp). n = 0 where v is the ratio of the thermal conductivity The first of equations (15) translates into 8B aT dT __-_2__=y a.2 ar ar Let q(r,t)
be the deviation
aT, -_E2_P az
of the interface
by B(r), the continuity Tp = T,
and
of the particle
dt3 6’T dr ar 1
from planarity,
of the heat flux and of
,
to that
(15) of the liquid
on z = B(r).
then K in equation
(V = k,/k).
(16) (6) is given by
(17)
Modelling and Asymptotic Analysis where the subscript perature
T denotes
at the interface
differentiation
z = n(r,t)
with respect
(equation
to r. In dimensionless
1+c2p2 1+&r3b97 717-T
where
cd
r and p describe
-AS2
P=
r = !AH,T,
(19)
6d3AHfTm.
the influence
of the front curvature
and the pressure
forth by the molecular forces on the local melting point, respectively. We proceed with an estimation of the order of magnitude of the various rameters
that
A M 10-15erg acteristic
emerged (lerg
length
form, the tem-
(5)) satisfies
T=Ts=l+
The two parameters
151
from the analysis.
We consider
= 10P7 J), (Y N”50erg/cm2
a typical
and particle
physical
radius
dimensionless
situation
pa-
[10,14] with
a M 10F3 cm. Then
scale is e M 10V7 cm which yields E M 10m4. For V z 10e4 cm/s,
put
the char-
K z 10-l cm2/s,
we obtain I’ M .13, ,8 z 1.6 x 10Y4, and v x 10-i’. Hence, and CllAHfTm z 3 x 10-gcm3/erg, appropriate scalings for the dimensionless parameters are w = ~~6, ,0 = eb, and I = O(1) where the hat symbol
denotes
O(1) quantities.
3. FRONT In this section,
we follow the analysis
of Cox and Brenner [17] to conduct an asymptotic analysis in the vicinity of the origin. For this purpose, we introduce
of equations (ll)-(13) and (15)-(18) the inner variable r = &R. This scaling system
of equations
and boundary dT -at
SHAPE
is dictated
conditions
by the form of equation
(14). The following
results:
dT 1 d ~‘6~ =E-Rc3R
(20)
(21) (22) The upper
boundary
is now given by R2 R4 z=H+~+E~+...=D(R).
On z = B(R), th e continuity
of temperature
dT dB dT ---_--~~ dR dR a.% The temperature
and of the heat flux yields
aT, dB c3T -__E_-z dR dR I [ dz
in the solid and liquid phases T=Ts=l+
(23)
at the interface
and
T = Tp.
(24)
z = q(R, t) is given by
VRR + cBg-3(R). 1 + cr]R2 I
(25)
Since the aim of this study is analyzing the effect of the disjoining pressure, we set the thermal conductance ratio Y to unity. This corresponds to a particle having the same thermal conductivity as the melt. Therefore, as far as thermal effects are concerned, the particle is indistinguishable from the melt. We solve the steady-state version of the above problem by expanding the independent variables, including the interface, in E as
L. HADJI
152
The reduced
problem
(E = 0) pertains
to the case of a planar
interface
and is described
by
72 +1, Tp = F(* - d) + To,
onH+2-
(23)
TS = Gsz + 1,
z I 0,
(29)
T(z) =
where AT = To - 1. Here AT/d liquid film and a portion profiles
because
The particle’s
the effect of the disjoining
The ratio of the temperature
pressure
H is the depth
gradient presence
difference
across a layer consisting at O(1) but enters
the temperature
AT over the depth
of the
does not affect the temperature
does not appear
i.e., O(E). Consequently,
AT -= d where
R2
is simply the temperature
of the particle.
next order in the calculations, the vertical coordinate.
(27)
profiles
d can be written
at the
are all linear as
AT, f AT, L+H
of the melt layer under
(30)
’ L = d - H, AT,
the particle,
in
and AT,
are the
temperature changes over the depths H and L, respectively (see Figure 1). In to the continuity of the heat flux at the particle-melt interface the O(1) contribution
dimensionless addition, implies
AT, _ AT, -E---H. By combining
equations
(30) and (31), we obtain d=H
Proceeding
to the O(E) problem,
we find that
[
(31)
an expression
I+%.
for the parameter
d, namely,
m 1
(32)
the temperature
perturbation
0 is given by
(33)
Application
of the heat energy
balance
at the solid-liquid
V[KT,-T].n=C
V+z [
interface
implies
1
arl
,
where K = ks/kl denotes the ratio of the thermal conductivity of the solid phase (ks) to that of the liquid phase (kL), C is the nondimensional latent heat of fusion, C = AHftcL/kLT,,, (of growth rate. The leading order term of the numerical order unity) and V is the dimensionless latter is calculated from equation (34) to get
The last term in equation (35) follows from equation (32). This expression for the growth velocity is similar to the one corresponding to the directional solidification stance without the particle’s presence with AT,/H being the thermal gradient in effect of the particle does not appear at this order of the calculations. At O(E) of we obtain an evolution equation for the interface perturbation q(R, t), namely,
dimensionless of a pure subthe melt. The equation (34),
(36)
Modelling
If we make the change of variable that
is bounded
and Asymptotic
z = Rv’m,
at x = 0 and satisfies
kind,
and Ko(x)
la(x)
the symmetry
respectively.
are the modified
Upon using
where The
the positive parameter
parameter
y depicts
condition
dy - Ko(x)
Bessel functions
2
(1 +yy2j3
y = I’/2AT,
the competition
$J
s s=
of equation
is introduced
dY
to simplify
the interfacial
1’ (37)
= AT, (37) reduces
(1 +-fY2)3
0
”
zero of the first and second
Ko(X)Ylb(Yl)
-
between
of order
(36),
= 0, is given by
YIoo(Y) o (N + (I’~/~AT)Y~)~
AT,, + AT,
cx)~oo(X)YKo(Y) dY
[S
solution
I
(32) and the fact that
ALH2AT,
q(x) =
153
then the steady-state
YKO(Y) O” (H + (I’~/~AT)Y~)~ where
Analysis
to
1
(38)
’
the expression
and thermal
effects.
for v(x). A plot
of the interface shape, represented by equation (38), is shown in Figure 2. The front profile is convex for p > 0 and concave otherwise. Far away from the origin, i.e., away from the particle’s position,
the interface
interface
shape,
dimensionless
approaches
equation
the planar
(38), takes
profile
the following
rapidly.
Note that
form when
written
the equation
in terms
for the
of the original
variables:
-aa”-------------’ 2 4
6
X
Figure 2. A plot of the scaled interface deflection, H2AZ’,q(z)/j~I, for three values of the parameter y: y = 0.05 (dash-dotted), y = 0.2 (dotted), and y = 2 (continuous line).
4. GROWTH
RATE
FOR CONTINUOUS
Now that the profile of the solid-liquid
interface
is determined,
REPULSION
we proceed with the derivation
of
an asymptotic representation for the gap thickness g(z). Upon using the expressions for the meltparticle boundary and the solid-liquid interface given by equations (23) and (38), respectively, we obtain g(x) = B(x) - q(x) If we neglect
any buoyancy
change
= H + 2
due to the thermal
(~Hx)~ ___ 8 expansion
_ rl(x)
1
(40)
of the melt then the particle,
assumed neutrally buoyant, is subject to two main forces, namely, the van der Waals force Fvdw, which is either compressive or repulsive, and the Stokes force Fvisc which opposes the particle’s movement [16]. These forces are given by
154
L. HADJI
where p is the melt’s dimensional
dynamic
gap separation.
V is the velocity
viscosity, Continuous
pushing
of the solidifying
of the particle
Fvdw = Fvisc. Upon using equation (41), the balance for the growth velocity resulting from the force balance:
provided equation
front,
by the moving
and g* is the
interface
of forces yields
occurs
the following
(42) of V,, on the order unity
where the dependence
on H. In the following,
the gap thickness
free parameter
H comes from the dependence
of
for V,, by making
use
we look for a simplified
solution
of the value of the gap thickness at the origin. This approximation will not alter the functional dependence of V’, on the physical variables which is one of the aims of this study. Moreover, given that major units),
the interface
contribution
profile decays
rapidly
to zero (the planar
to the forces comes from near the origin.
we make use of Brenner’s
analytical
solution
interface),
we expect
that
the
For g*(O) < 1 (in some appropriate
[16] for the Stokes force
6npVa2
Fviscx ~ while the disjoining
pressure
(43)
’
force is given by [18]
F Upon equating
g*(O)
Ma
(44)
vdw = 6 (g* (0))2 ’
the two forces, we obtain
I-4
Kq(H) = 36rpae[H - q(O)]
’
where we have used the fact that g*(O) = ![H - q(O)] with C being defined asymptotic representation for V,, is, thus, given by
Kq(W
where Z(y)(=
(10). An
JAI 1
- -36rpae H
n(O)) is given by Z(Y) =
Note that
by equation
the function
Z(y) satisfies
O” YKo(Y) I0
(47)
(I + YY2)3’
0 5 Z(y) 5 1, Z(y) + 1 as y -+ 0 and Z(y) -+ 0 sharply
as
y --f co. The O(E) contribution that appears in equation (46) represents the influence of the interfacial deformation on V,,. This contribution is shown to depend on the disjoining pressure parameter 6, the temperature difference across the melt film AT,, the parameter y = I’/2AT,, and the dimensionless thickness H. Thus, one may undertake a qualitative analysis of the effect of each one of these parameters on V,, directly from equation (46). Upon using the facts that efi = p and that the parameter H was related to the dimensional gap thickness by H = h,/e, we write equation (46) as (keeping in mind that it is valid only asymptotically)
(48) In our expression decreasing
for Veq, the dependence
with H because
on the gap thickness
the term (&?(y)/ATmH3)
H is such that
< 1 and H = O(1). Thus,
V,, is monotonic Veq(H) defined
Modelling
by equation
(46) would attain
the asymptotic
constraint
we may postulate
that
and Asymptotic
its maximum
that
value at the smallest
H be order unity.
the maximum
Analysis
155
value of H subject
possible
From the asymptotic
of V,, is attained
analysis
point
at H = 1, which corresponds
to
of view,
to h,
= C,
to obtain K+&[1+~]. From
a physical
defined
(49)
to the critical distance of view, h, = constant x e. This corresponds et al. [4]. This critical distance is determined and Rogge [ll] and Shanguan
point
by Pijtschke
by the range of the van der Waals forces and depends on the particular Upon using equations (10) and (19) for JJ and P, respectively, we obtain v =
(B12’3(241’3
c
where AT, depicts
* is the dimensional
36rpa4/3 temperature
difference
of V, on the physical
the dependence
2fwf)Q aAHfTAAT,*
experimental
1’
(50)
across the melt film. Equation
parameters,
situation.
is the main motivation
(50), which
of the foregoing
analysis.
5. CONCLUSION A new approach and a solidifying
was undertaken interface.
ods, is used to investigate
to investigate
The approach, the influence
the interaction
between
which is based on the application of the disjoining
pressure
an insoluble
particle
of asymptotic
on particle
engulfment.
methAn
insoluble and neutrally buoyant spherical particle is assumed to be in the near-contact region. The latter pertains to a situation when the gap separation between the particle and the planar solid-liquid interface is much smaller than the particle’s radius. In such a situation, length scale, which is determined from a balance between the pressures induced
the relevant by the front
curvature, as a result of the Gibbs-Thomson effect, and the disjoining pressure in the melt film behind the particle, is given by equation (10). The nondimensionalization of the equations of thermal conduction in the melt, solid, and particle, which incorporate the moving interface, and corresponding solidification boundary conditions give rise to several dimensionless parameters. Of those, only two stand out in the analysis, namely, the disjoining pressure parameter p and the front curvature parameter P. Using a small-gap asymptotic analysis, we have derived an expression for the front shape presence
(see equation
to the disjoining
which is uniformly (39)). The amount
pressure
parameter
valid for r > 0 and which accounts of deflection
/? but is inversely
of the solid-liquid proportional
interface
for the particle’s is proportional
to the temperature
difference
across the melt film AT,. The interface profile is utilized to derive an asymptotic expression for the gap width. However, only the value of the latter at the origin is used in evaluating the leading order terms of the hydrodynamic and disjoining pressure forces acting on the particle. The resultant of these two forces yield an asymptotic representation for the equilibrium velocity (see equation (45)). A sort of maximization procedure is then adopted to find an expression for V,. Given that V,. decreases with H, we postulated that the maximum velocity is attained at the smallest possible H such that H is order unity. dependence of V, on the various parameters.
This led to equation
(50) which shows the
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