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Determining Alloy Nucleation Core Origin and Grain Refinement Strategy Based on the Dependence Degree of Content Difference

What is nucleation core origin during alloy solidification, especially for equiaxed grains? Different dependence degrees of the magnitude or occurrence of element content variation could shed light on this long-standing issue in actual large ingots. Here, based on etched surface height and grayscale, element content distributions within the solid fraction in continuous casting billets and additive manufacturing samples are first obtained by only a two-dimensional surface. Then, combined with the phylogenetic trees, the rank correlation is applied to measure the dependence of content differences during initial solidification. Assessments of external dependence degrees are helpful to determine nucleation core origin and low internal dependence degree facilitates grain refinement. Moreover, in continuous casting, some nucleation cores in the central equiaxed grain zone are confirmed to originate from the edge-chilled zone and high equiaxed grain area ratio under a low superheat, which is attributed to the low ratio of temperature gradient to growth rate rather than remelting fewer cores originating from the chilled zone. In addition, the floating behavior of separated grains originating from the chilled zone can be affected by gravity force, but these grains should be more active when increasing the casting superheat that may weaken the influence of gravity to a certain extent.