The origin of freckles during unidirectional solidification is studied in a transparent, low melting model system, 30 wt pct
NH
4C1-H
2O. In 30NH
4Cl-H
2O, freckles are caused by upward flowing liquid jets in the mushy zone. The jets erode the mushy zone causing localized segregation
and start new grains by producing dendritic debris. It is shown that the jets observed in 30NH
4C1-H
2O are free convection resulting from a density inversion in the mushy zone. A comparison of driving force, thermal transport
effects and solute transport effects in 30NH
4C1-H
2O and metallic systems shows that jets are possible in metallic alloys where light elements segregate normally or heavy elements
segregate inversely. It is concluded that freckles in unidirectionally solidified castings and vacuum consumable-electrode
ingots are caused by convective jets. It is shown that the tendency to freckle is greatest in alloys with a large density
inversion, high thermal diffusivity, low solute diffusivity, and low viscosity. For a given alloy, the driving force for freckling
is proportional to the inverse square of the thermal gradient. Erosion by the jets is decreased by increasing the thermal
gradient and growth rate. The location of freckles is influenced by mushy zone curvature.
Formerly Research Assistant at the Advanced Materials Research and Development Laboratory
An erratum to this article is available at http://dx.doi.org/10.1007/BF03037879.