Modelling and simulation of the freeze casting process with the phase-field method

The freeze casting process is a novel manufacturing method for both near net-shape parts as well as directed porous structures as employed by filters and implants. Depending on the choice of liquid and processing conditions a very wide range of pore shapes and sizes can be achieved. In order to predict the resulting microstructure, a phase-field model is developed on the basis of the grand potential formalism. The model and its parametrization approximate the freeze-casting process of water by linking its thermodynamics with established theory. Directional solidification simulations with varying suspension concentrations, velocities and temperature gradients are carried out. From these, microstructural lengths are determined and linked with the processing parameters, so as to derive linkages between the microstructure and the processing conditions.

Automated summary

The freeze casting process is a novel manufacturing method used for producing near net-shape parts and directed porous structures, with a wide range of pore shapes and sizes achievable by choosing different liquids and processing conditions. A phase-field model is developed to predict the resulting microstructure, linking thermodynamics with established theory. Directional solidification simulations are conducted to determine microstructural lengths and their linkages with processing parameters, establishing relationships between microstructure and processing conditions.