Phase-field modeling of microstructural pattern formation during directional solidification of peritectic alloys without morphological instability

Rotating Directional Solidification of Ternary Eutectic Microstructures in Bi-In-Sn: A Phase-Field Study

For the first time, the experimental processing condition of a rotating directional solidification is simulated in this work, by means of a grand-potential-based phase-field model. To simulate the rotating directional solidification, a new simulation setup with a rotating temperature field is introduced. The newly developed configuration can be beneficent for a more precise study of the ongoing adjustment mechanisms during temperature gradient controlled solidification processes. Ad hoc, the solidification of the ternary eutectic system Bi-In-Sn with three distinct solid phases α,β,δ is studied in this paper. For this system, accurate in situ observations of both directional and rotating directional solidification experiments exist, which makes the system favorable for the investigation. The two-dimensional simulation studies are performed for both solidification processes, considering the reported 2D patterns in the steady state growth of the bulk samples. The desired αβαδ phase ordering repeat unit is obtained within both simulation types. By considering anisotropy of the interfacial energies, experimentally reported tilted lamellae with respect to normal vectors of the solidification front, as well as predominant role of αβ anisotropy in tilting phenomenon, are observed. The results are validated by using the Jackson-Hunt analysis and by comparing with the existing experimental data. The convincing agreements indicate the applicability of the introduced method.

On oscillatory microstructure during cellular growth of directionally solidified Sn-36at.%Ni peritectic alloy

An oscillatory microstructure has been observed during deep-cellular growth of directionally solidified Sn–36at.%Ni hyperperitectic alloy containing intermetallic compounds with narrow solubility range. This oscillatory microstructure with a dimension of tens of micrometers has been observed for the first time. The morphology of this wave-like oscillatory structure is similar to secondary dendrite arms, and can be observed only in some local positions of the sample. Through analysis such as successive sectioning of the sample, it can be concluded that this oscillatory microstructure is caused by oscillatory convection of the mushy zone during solidification. And the influence of convection on this oscillatory microstructure was characterized through comparison between experimental and calculations results on the wavelength. Besides, the change in morphology of this oscillatory microstructure has been proved to be caused by peritectic transformation during solidification. Furthermore, the melt concentration increases continuously during solidification of intermetallic compounds with narrow solubility range, which helps formation of this oscillatory microstructure.

Multi-phase-field analysis of short-range forces between diffuse interfaces

We characterize both analytically and numerically short-range forces between spatially diffuse interfaces in multi-phase-field models of polycrystalline materials. During late-stage solidification, crystal-melt interfaces may attract or repel each other depending on the degree of misorientation between impinging grains, temperature, composition, and stress. To characterize this interaction, we map the multiphase-field equations for stationary interfaces to a multidimensional classical mechanical scattering problem. From the solution of this problem, we derive asymptotic forms for short-range forces between interfaces for distances larger than the interface thickness. The results show that forces are always attractive for traditional models where each phase-field represents the phase fraction of a given grain. Those predictions are validated by numerical computations of forces for all distances. Based on insights from the scattering problem, we propose a multi-phase-field formulation that can describe both attractive and repulsive forces in real systems. This model is then used to investigate the influence of solute addition and a uniaxial stress perpendicular to the interface. Solute addition leads to bistability of different interfacial equilibrium states, with the temperature range of bistability increasing with strength of partitioning. Stress in turn, is shown to be equivalent to a temperature change through a standard Clausius-Clapeyron relation. The implications of those results for understanding grain boundary premelting are discussed.

Phase-field modelling for metals and colloids and nucleation therein-an overview

Phase-field modelling, as it is understood today, is still a young discipline in condensed matter physics, which established itself for that class of systems in condensed matter physics, which can be characterized by domains of different phases separated by a distinct interface. Driven out of equilibrium, their dynamics results in the evolution of those interfaces, during which those might develop into well-defined structures with characteristic length scales at the nano-, micro- or mesoscale. Since the material properties of such systems are, to a large extent, determined by those small-scale structures, acquiring a precise understanding of the mechanisms that drive the interfacial dynamics is a great challenge for scientists in this field. Phase-field modelling is an approach that allows us to tackle this challenge simulation-based. This overview summarizes briefly the essentials of the conceptual background of the phase-field method, as well as recent issues the phase-field community is focusing on, as far as they are related to nucleation. To that end a brief introduction to the basic understanding underlying the diffuse interface description, which is the conceptual backbone of phase-field modelling, is given at the beginning, followed by a detailed picture of its achievements so far in applications to nucleation phenomena in metals and colloids. Within the most relevant fields of condensed matter physics, approached by phase-field modelling until now, applications to metallic systems are a traditional domain of phase-field modelling and nucleation phenomena therein have been addressed by several groups. This paper provides an overview of these. Advances in the field of colloidal systems, on the other hand, are only more recent and are addressed here in the context of contributions to soft matter physics in general.

Phase field modeling of CH4hydrate conversion into CO2hydrate in the presence of liquid CO2

We present phase field simulations to estimate the conversion rate of CH(4) hydrate to CO(2) hydrate in the presence of liquid CO(2) under conditions typical for underwater gas hydrate reservoirs. In the computations, all model parameters are evaluated from physical properties taken from experiment or molecular dynamics simulations. It has been found that hydrate conversion is a diffusion controlled process, as after a short transient, the displacement of the conversion front scales with t(1/2). Assuming a diffusion coefficient of D(s) = 1.1 x 10(-11) m(2) s(-1) in the hydrate phase, the predicted time dependent conversion rate is in reasonable agreement with results from magnetic resonance imaging experiments. This value of the diffusion coefficient is higher than expected for the bulk hydrate phase, probably due to liquid inclusions remaining in the porous sample used in the experiment.

Quantitative phase-field modeling of two-phase growth

A phase-field model that allows for quantitative simulations of low-speed eutectic and peritectic solidification under typical experimental conditions is developed. Its cornerstone is a smooth free-energy functional, specifically designed so that the stable solutions that connect any two phases are completely free of the third phase. For the simplest choice for this functional, the equations of motion for each of the two solid-liquid interfaces can be mapped to the standard phase-field model of single-phase solidification with its quartic double-well potential. By applying the thin-interface asymptotics and by extending the antitrapping current previously developed for this model, all spurious corrections to the dynamics of the solid-liquid interfaces linear in the interface thickness W can be eliminated. This means that, for small enough values of W, simulation results become independent of it. As a consequence, accurate results can be obtained using values of W much larger than the physical interface thickness, which yields a tremendous gain in computational power and makes simulations for realistic experimental parameters feasible. Convergence of the simulation outcome with decreasing W is explicitly demonstrated. Furthermore, the results are compared to a boundary-integral formulation of the corresponding free-boundary problem. Excellent agreement is found, except in the immediate vicinity of bifurcation points, a very sensitive situation where noticeable differences arise. These differences reveal that, in contrast to the standard assumptions of the free-boundary problem, out of equilibrium the diffuse trijunction region of the phase-field model can (i) slightly deviate from Young's law for the contact angles, and (ii) advance in a direction that forms a finite angle with the solid-solid interface at each instant. While the deviation (i) extrapolates to zero in the limit of vanishing interface thickness, the small angle in (ii) remains roughly constant, which indicates that it might be a genuine physical effect, present even for an atomic-scale interface thickness.

Eutectic colony formation: a phase-field study

Eutectic two-phase cells, also known as eutectic colonies, are commonly observed during the solidification of ternary alloys when the composition is close to a binary eutectic valley. In analogy with the solidification cells formed in dilute binary alloys, colony formation is triggered by a morphological instability of a macroscopically planar eutectic solidification front due to the rejection by both solid phases of a ternary impurity that diffuses in the liquid. Here we develop a phase-field model of a binary eutectic with a dilute ternary impurity. We investigate by dynamical simulations both the initial linear regime of this instability, and the subsequent highly nonlinear evolution of the interface that leads to fully developed two-phase cells with a spacing much larger than the lamellar spacing. We find a good overall agreement with our recent linear stability analysis [M. Plapp and A. Karma, Phys. Rev. E 60, 6865 (1999)], which predicts a destabilization of the front by long-wavelength modes that may be stationary or oscillatory. A fine comparison, however, reveals that the assumption commonly attributed to Cahn that lamellae grow perpendicular to the envelope of the solidification front is weakly violated in the phase-field simulations. We show that, even though weak, this violation has an important quantitative effect on the stability properties of the eutectic front. We also investigate the dynamics of fully developed colonies and find that the large-scale envelope of the composite eutectic front does not converge to a steady state, but exhibits cell elimination and tip-splitting events up to the largest times simulated.

Novel pattern forming process due to the coupling of convection and phase change

We present a novel mechanism of pattern formation behind a flat interface during directional solidification of peritectic alloys. It is shown through computational modeling that irregular oscillatory thermosolutal convection can develop in the vertical Bridgman system, even with bottom seeding and bottom cooling. The coupling of the flow oscillation near the interface with solidification leads to ordered layered structures in the solidified crystal, which agree closely with earlier experimental results.

Nucleation and bulk crystallization in binary phase field theory

We present a phase field theory for binary crystal nucleation. In the one-component limit, quantitative agreement is achieved with computer simulations (Lennard-Jones system) and experiments (ice-water system) using model parameters evaluated from the free energy and thickness of the interface. The critical undercoolings predicted for Cu-Ni alloys accord with the measurements, and indicate homogeneous nucleation. The Kolmogorov exponents deduced for dendritic solidification and for "soft impingement" of particles via diffusion fields are consistent with experiment.