This review article on the microstructural characterization and numerical modeling of heat and fluid flow during solidification of aluminium alloys seeks to review the effects of solidification parameters and their resultant microstructures on the quality of cast components. Continuous casting and direct chill casting processes which are the most industrial methods for the production of aluminium and steel ingots are given particular considerations. Different groups of aluminium alloys, their properties, improvements and special applications are analyzed. Microstructure characterization which reveals the constituents of the cast structures such as primary phase of the matrix (a-phase), secondary phases (like b-phase), intermetallic compounds, primary and secondary dendrite arm spacing, micro-segregations, porosities and impurities within the castings, grain boundaries, their sizes, morphologies and distribution of these constituents and phases within the cast microstructure are reviewed. The physics of fluid flow, heat flow and energy dissipation during solidification phenomenon are studied. Different techniques for numerical modeling and simulation of heat and fluid flow during casting, especially within the solidification phase change region (the mushy zone) are also reviewed. The most popular numerical methods and solution algorithms for solving solidification phase change problems are considered.

numerical methods, characterization, aluminum alloys, microstructure, continuous casting, direct Chill casting, solidification, modeling and simulation.