Microstructure development during rapid alloy solidification

Ji, Kaihua; Clarke, Amy J.; McKeown, Joseph T.; Karma, Alain

doi:10.1557/s43577-024-00717-6

Microstructure development during rapid alloy solidification

Journal Article · Tue May 14 00:00:00 EDT 2024 · MRS Bulletin

DOI:https://doi.org/10.1557/s43577-024-00717-6· OSTI ID:2350715

Ji, Kaihua; Clarke, Amy J.; McKeown, Joseph T.; Karma, Alain

Abstract

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.

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Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States); Los Alamos National Laboratory (LANL), Los Alamos, NM (United States)

Sponsoring Organization:: USDOE; USDOE National Nuclear Security Administration (NNSA); USDOE Office of Science (SC), Basic Energy Sciences (BES)

Grant/Contract Number:: 89233218CNA000001; AC52-07NA27344; SC0020870; SC0020895

OSTI ID:: 2350715

Alternate ID(s):: OSTI ID: 2375437
OSTI ID: 2406653

Report Number(s):: LA-UR--24-21604; LLNL--JRNL-859968; PII: 717

Journal Information:: MRS Bulletin, Journal Name: MRS Bulletin Journal Issue: 6 Vol. 49; ISSN 0883-7694

Publisher:: Cambridge University Press (CUP)Copyright Statement

Country of Publication:: United States

Language:: English

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