In order to investigate the solute distribution and freckles formation during directional solidification of superalloy ingots, a mathematical model with coupled solution of flow field, solute and temperature distribution was developed. Meanwhile, the reliability of this model was verified by the experimental and simulation results in relevant literatures. The three-dimensional directional solidification process of Ni-5.8wt%Al-15.2wt%Ta superalloy ingot was simulated, and then the dynamic growth

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... of solute enrichment channels was demonstrated inside the ingot. Freckles formation under different cooling rates was studied, and the local segregation degree inside the ingot was obtained innovatively after solidification. The results show that the number of freckles formed at the top gradually decreases, and so do the degree of solute enrichment at these freckles with the increase of cooling rate. Moreover, the relative and volume-averaged segregation ratio is defined to describe the segregation degree inside the ingot. The span of relative segregation ratio for positive segregation is wider than that for negative segregation, but it accounts for less of total volume. As the cooling rate increases from 0.1 K/s to 1.0 K/s, the proportion of weak segregation (-20%~20%) increases significantly from 26% to 41%, so that the segregation degree is weakened in general. By analyzing the freckles formation and segregation degree inside the ingot, the numerical simulation results can provide a theoretical basis for optimizing the actual production process to suppress the freckle defects.