Mathematical modeling is routinely used in the process development and production of advanced aerospace alloys to gain greater insight into system dynamics and to predict the effect of process modifications or upsets on final properties. This article describes the application of a 2-D mathematical VAR model presented in previous LMPC meetings. The impact of process parameters on melt pool geometry, solidification behavior, fluidflow and chemistry in Ti-6AI-4V ingots will be discussed. Model predictions were first validated against the measured characteristics of industrially produced ingots, and process inputs and model formulation were adjusted to match macro-etched pool shapes. The results are compared to published data in the literature. Finally, the model is used to examine ingot chemistry during successive VAR melts.
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