Effect of Multi-Source Ultrasonic on Segregation of Cu Elements in Large Al–Cu Alloy Cast Ingot

The structure and composition of large-scale Al–Cu alloy ingots are inhomogeneous, and the segregation of (especially) elemental Cu negatively affects the uniformity and stability of the subsequent components. In this work, four ultrasonic generators were used to manipulate solidification/microstructures of cylindrical Al–Cu ingots (1250 mm in diameter; 3500 mm in length). The influence of ultrasonic configuration on both solidification microstructures and solute macrosegregation was investigated by changing the position parameters of generators for a fixed power. The results revealed that when the ultrasound is applied close to the center (I) from the 1/2 radius (II), the grain structure of the center undergoes significant refinement, degree of positive segregation in the center can be reduced, segregation index decreased from 0.2 to 0.15, and range of positive segregation in the center decreased from 200 to 150 mm. The segregation of elemental Cu was weakened by the combined effects of the ultrasound on the flow, heat transfer, and grain movement.