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Abstract
Three-dimensional numerical simulations are performed of freckling during directional solidification of a binary metal alloy. The purpose of the study is to evaluate the sensitivity of the predictions to the grid resolution. Detailed results are provided for the liquid concentration, solid fraction, and liquid velocity distributions at different times. It is shown that, while it is possible to simulate freckle formation with a relatively coarse grid, many local details are predicted inaccurately. The results for the finest grid indicate that complete grid independence is difficult to achieve given present-day computing resources.