Crystal Growth in Fluid Flow: Nonlinear Response Effects

We investigate crystal-growth kinetics in the presence of strong shear flow in the liquid, using molecular-dynamics simulations of a binary-alloy model. Close to the equilibrium melting point, shear flow always suppresses the growth of the crystal-liquid interface. For lower temperatures, we find that the growth velocity of the crystal depends non-monotonically on the shear rate. Slow enough flow enhances the crystal growth, due to an increased particle mobility in the liquid. Stronger flow causes a growth regime that is nearly temperature-independent, in striking contrast to what one expects from the thermodynamic and equilibrium kinetic properties of the system, which both depend strongly on temperature. We rationalize these effects of flow on crystal growth as resulting from the nonlinear response of the fluid to strong shearing forces.Comment: to appear in Phys. Rev. Material

Nucleation and phase selection in undercooled melts: Magnetic alloys of industrial relevance (MAGNEPHAS)

Studies of phase selection and microstructure evolution in high-performance magnetic materials are an urgent need for optimization of production routes. Containerless solidification experiments by electromagnetic levitation and drop tube solidification were conducted in undercooled melts of Fe-Co, Fe-Ni soft magnetic, and Nd-Fe-B hard magnetic alloys. Melt undercooling under microgravity was achieved in the TEMPUS facility during parabolic flight campaigns. For Fe-Co and Fe-Ni alloys significant effects of microgravity on metastable phase formation were discovered. Microstructure modifications as well as metastable phase formation as function of undercooling and melt flow were elucidated in Nd-Fe-B. Modeling of solidification processes, fluid flow and heat transfer provide predictive tools for microstructure engineering from the melt. They were developed as a link between undercooling experiments under terrestrial and microgravity conditions and the production routes of magnetic materials

Experimental and Numerical Modeling of Segregation in Metallic Alloys

International audienceElectromagnetic levitation (EML) has been used as an experimental technique for investigating the effect of the nucleation and cooling rate on segregation and structure formation in metallic alloys. The technique has been applied to aluminum-copper alloys. For all samples, the primary phase nucleation has been triggered by the contact of the levitated droplet with an alumina plate at a given undercooling. Based on the recorded temperature curves, the heat extraction rate and the nucleation undercooling for the primary dendritic and the secondary eutectic structures have been determined. Metallurgical characterizations have consisted of composition measurements using a scanning electron microscope (SEM) equipped with energy dispersive X-ray spectrometry and the analysis of SEM images. The distribution maps drawn for the composition, the volume fraction of the eutectic structure, and the dendrite arm spacing (DAS) reveal strong correlations. Analysis of the measurements with the help of a cellular-automaton (CA)-finite-element (FE) model is also proposed. The model involves a new coupling scheme between the CA and FE methods and a segregation model accounting for diffusion in the solid and liquid phases. Extensive validation of the model has been carried out on a typical equiaxed grain configuration, i.e., considering the free growth of a mushy zone in an undercooled melt. It demonstrates its capability of dealing with mass exchange inside and outside the envelope of a growing primary dendritic structure. The model has been applied to predict the temperature curve, the segregation, and the eutectic volume fraction obtained upon single-grain nucleation and growth from the south pole of a spherical domain with and without triggering of the nucleation of the primary solid phase, thus simulating the solidification of a levitated droplet. Predictions permit a direct interpretation of the measurements

Microstructure and Phase Formation in a Rapidly Solidified Laser-Deposited Ni-Cr-B-Si-C Hardfacing Alloy

In this study, microstructural evolutions and phase selection phenomena during laser deposition of a hardfacing Ni-Cr-B-Si-C alloy at different processing conditions are experimentally investigated. The results show that even minor variations in the thermal conditions during solidification can modify the type and morphology of the phases. Higher undercoolings obtained at faster cooling rates suppressed the primary borides and encouraged floret-shape mixtures of Ni and Cr5B3 via a metastable reaction. Variations in the boride phases are discussed in terms of nucleation-and growth-controlled phase selection mechanisms. These selection processes also influenced the nature and proportion of the Ni-B-Si eutectics by changing the amount of the boron available for the final eutectic reactions. The results of this work emphasize the importance of controlling the cooling rate during deposition of these industrially important alloys using laser beam or other rapid solidification techniques. (C) The Minerals, Metals & Materials Society and ASM International 201