fractory (Low chill), and 3) heat flow from the molten ‘metal into the solidifying shell. The resultant strue= ture depends a great deal upon the balance between these three quantities. Under normal circumstances, the meniscus alternately hangs up and breaks loose from the overhanging refractory face making the proc- 85 a discontinuous one, The resultant macrostructure may look Like that shown in Fig. 2. It is then typical for the structure to have cyclic features, with the meniscus extending inward over a finite distance, As~ sociated with this mode of solidification is consider- able segregation manifested by high concentrations of some elements within the cyclic surface zone and low concentrations of alloying elements adjacent to that surface band. Although such a macrostructure is by ‘no means typical of all ingot cast by the level-pour process, it is the basie solidification mechanism which ‘will now be presented and analyzed. Let us assume that an ingot is being cast in a mold ‘such as shown in Fig. 1 and detailed in Fig. 3. At the top of the mold, heat flow conditions as described Fig. 2—Macrostructure at surfase of 6063 alloy 9 jn, diam Ingot. Longitudinal section. Magnification 10 times. 3362-WOLUME 1, DECEMBER 1970 will cause the meniseus to grow away from the mold wall. As the solid ingot shell moves down (stages a and 6 in Fig. 3), the meniscus remain in contact with the horizontal header face. Consequently, a hollow space forms above the meniscus and actually increases since contact between the meniscus and the header blocks flow of molten metal into that space, As cast- ing continues, the meniscus can grow to the edge of the protruding header (stage c). Under certain condi- tions of heat extraction, the innermost dimension of the meniscus becomes the outer ingot surface because ‘molten metal continues to be blocked from filling the ‘empty corner (stages q and ¢). Eventually, however, the decreased chill caused by the large empty corner leads to a temperature rise of that thin shell, liquid ‘metal finally breaks through (stage /), fills the avail- tle space andthe process then repeats ise (wage #) “Phe sequence ilustrated in Fig. 3 was taken from a 9 in, diam ingot of 6063 alloy cast at a speed of 4 in. per min. The time interval between two successive Stages, as determined from the eyele time of 1.5 sec, is 0.28 sec. We can now examine more closely the macrostructure itself to corroborate the foregoing ex- planation and to obtain additional information about the Kinetics of this discontinuous solidification process. ‘Alter the meniscus has completed its growth under the header overhang face, exhibiting a fairly uniform and equilibrium grain structure (stages a toc), the thin shell, forming now at a distance trom the mold wall equivalent to the header overhang, grows at a considerably lower rate than the mentacus. Conse ‘quently, the rate of solute rejection to the liquid be comes high. The result is a solid which is low in solute. This evidence is clear in the macrostructure of stages d and e. Having reached finally a state of mechanical wealness due to thermal conditions, tie shell yields and liquid fills the space. The force of bending is often documented in the outward pointing top of this light-colored band as illustrated by the macrostructure shown in Fig. 4 and designated by the arrow. The rejected solute atthe intial solid/liquid interface bursts through the shell, Fig. 3(f), and sol- {difies mainly by chill from the previously solidified surface. Depending on the amount of rejected solute present, a layer of metal concentrated with alloying elements can extend to the mold wall. The structure of the remaining surface shell solidifies in normal fashion, ‘The cyclic character of solidification near the sur- ig. 3~Mode! of discontinuous solidfieation juring casting of 6063 alloy 9 In. diam ingot. METALLURGICAL TRANSACTIONS