Numerical simulation of microstructure and microporosity morphology in directional solidification of aluminum-copper alloys: Effect of copper content and withdrawal rate

• A 2D cellular automaton model accurately simulates microporosity formation in Al-Cu alloys, validated by directional solidification experiments. • Copper content significantly influences microporosity growth through its effects on liquidus temperature, dendrite morphology, and hydrogen solubility. • Withdrawal rate affects microporosity nucleation by altering cooling rates and dendritic growth rates, leading to distinct microporosity characteristics. • The model provides a cost-effective tool for predicting microstructure and microporosity, aiding in process optimization for high-performance aluminum alloys.