Microstructure development during rapid alloy solidification

doi:10.1557/s43577-024-00717-6

Microstructure development during rapid alloy solidification

2024-05-14

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DOI：10.1557/s43577-024-00717-6

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Solidification processing of structural alloys can take place over an extremely wide range of solid-liquid interface velocities spanning six orders of magnitude, from the low-velocity constitutional supercooling limit of microns/s to the high-velocity absolute stability limit of m/s. In between these two limits, the solid-liquid interface is morphologically unstable and typically forms cellular-dendritic microstructures, but also other microstructures that remain elusive. Rapid developments in additive manufacturing have renewed the interest in modeling the high-velocity range, where approximate analytical theories provide limited predictions. In this article, we discuss recent advances in phase-field modeling of rapid solidification of metallic alloys, including a brief description of state-of-the-art experiments used for model validation. We describe how phase-field models can cope with the dual challenge of carrying out simulations on experimentally relevant length- and time scales and incorporating nonequilibrium effects at the solid-liquid interface that become dominant at rapid rates. We present selected results, illustrating how phase-field simulations have yielded unprecedented insights into high-velocity interface dynamics, shedding new light on both the absolute stability limit and the formation of banded microstructures that are a hallmark of rapid alloy solidification near this limit. We also discuss state-of-the-art experiments used to validate those insights.

Keywords:

Rapid solidification

Simulation

Microstructure

Additive manufacturing

Transmission electron microscopy (TEM)

Microstructure development during rapid alloy solidification

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