Anomalous kinetics, patterns formation in recalescence, and final microstructure of rapidly solidified Al-rich Al-Ni alloys

Copyright © 2022 The Authors. From thermodynamical consideration, rather a monotonically increasing crystal growth velocity with increasing undercooling is expected in the crystallization of liquids, mixtures, and alloys [P.K. Galenko and D. Jou, Physics Reports 818 (2019) 1]. By contrast to this general theoretical statement, Al-rich Al-Ni alloys show an anomalous solidification behavior: the solid-liquid interface velocity slows down as the undercooling increases [R. Lengsdorf, D. Holland-Moritz, D. M. Herlach, Scripta Materialia 62 (2010) 365]. It is also found that besides the anomalous growth behaviour, changes in the shape of the recalescence front as the growth front morphology occur. In the light of recent measurements in microgravity with an Al-25at.% Ni alloy sample onboard the International Space Station (ISS) results confirming this anomalous behavior as an unexpected trend in solidification kinetics are presented. The measurements show multiple nucleation events forming the growth front, a mechanism that has been observed for the first time in Al-Ni alloys [D. Herlach et al., Physical Review Materials 3 (2019) 073402; M. Reinartz et al. JOM 74 (2022) 2420] and summarized with detailed analysis in the present publication over a wider range of concentrations. Particularly, the experimental measurements and obtained data directly demonstrate that the growth front does thus not consist of dendrite tips (as in usual rapid solidifying samples), but of newly forming nuclei propagating along the sample surface in a coordinated manner. Theoretical analysis on intensive nucleation ahead of crystal growth front is made using the previously developed model [D.V. Alexandrov, Journal of Physics A: Mathematical and Theoretical 50 (2017) 345101]. Using equations of this model, quantitative calculations confirm the interpretation of experimentally observed propagation of the recalescence front and obtained data on the microstructure of droplets solidified in electromagnetic levitation facility (EML) on the Ground, under reduced gravity during parabolic flights, and in microgravity conditions onboard the ISS.European Space Agency (ESA) within the project NEQUISOL under contract No. 15236/02/NL/SH for experimental measurements under reduced gravity and by RSF under project No. 21-19-00279 for theoretical modeling; German Space Center - Space Administration under contract No. 50WM1941; German Science Foundation (DFG) under the Project GA 1142/11-1 for experimental measurements on the Ground

Dendrite growth in undercooled Al-rich Al-Ni melts measured on Earth and in Space

The dendrite growth velocity in Al₇₅Ni₂₅ melts has been measured in a containerless procedure as a function of undercooling using an electromagnetic levitation technique both in the Earth laboratory and in Space on board the International Space Station. The growth shows an anomalous behavior inasmuch as the growth velocity decreases with increasing undercooling, confirming previous experiments on Earth. Within the scatter of experimental data, results obtained on Earth and in Space do not show significant differences. Thus, convection effects as the origin of the anomalous growth characteristics can be excluded. However, high-speed video recording exhibits multiple nucleation events in front of the growing solid-liquid interface. This effect is identified as the origin of the anomalous dendrite growth characteristics in undercooled melts of Al-rich Al-Ni melts

Simulation of Intermetallic Solidification using Phase-Field Techniques

We present current ideas towards developing a phase-field model appropriate to the solidification of intermetallic phases. Such simulation presents two main challenges (i) dealing with faceted interfaces and (ii) the complex sub-lattice models used to describe the thermodynamics of such phases. Although models are already existent for the simulation of faceted crystals, some of these can be shown to produce highly unrealistic Wulff shapes. The model present here uses a parameterization of the Wulff shape as a direct input to the model, allowing the simulation of arbitrary crystal shapes. In addition, an anti-trapping current that can be used with arbitrary (including sub-lattice) thermodynamics is presented. Such antitrapping currents are vital in the simulation of intermetallic phases where the steep liquidus slope means small deviations in solute partitioning behaviour can translate to a significant change in tip undercooling

Phase-field modeling of eutectic structures on the nanoscale: the effect of anisotropy

This is a post-peer-review, pre-copyedit version of an article published in Journal of Materials Science. The final authenticated version is available online at: https://doi.org/10.1007/s10853-017-0853-8A simple phase-field model is used to address anisotropic eutectic freezing on the nanoscale in two (2D) and three dimensions (3D). Comparing parameter-free simulations with experiments, it is demonstrated that the employed model can be made quantitative for Ag-Cu. Next, we explore the effect of material properties, and the conditions of freezing on the eutectic pattern. We find that the anisotropies of kinetic coefficient and the interfacial free energies (solid-liquid and solid-solid), the crystal misorientation relative to pulling, the lateral temperature gradient, play essential roles in determining the eutectic pattern. Finally, we explore eutectic morphologies, which form when one of the solid phases are faceted, and investigate cases, in which the kinetic anisotropy for the two solid phases are drastically different