Pattern stability and trijunction motion in eutectic solidification

Interphase anisotropy effects on lamellar eutectics: a numerical study

In directional solidification of binary eutectics, it is often observed that two-phase lamellar growth patterns grow tilted with respect to the direction z of the imposed temperature gradient. This crystallographic effect depends on the orientation of the two crystal phases α and β with respect to z. Recently, an approximate theory was formulated that predicts the lamellar tilt angle as a function of the anisotropy of the free energy of the solid(α)-solid(β) interphase boundary. We use two different numerical methods-phase field (PF) and dynamic boundary integral (BI)-to simulate the growth of steady periodic patterns in two dimensions as a function of the angle θ(R) between z and a reference crystallographic axis for a fixed relative orientation of α and β crystals, that is, for a given anisotropy function (Wulff plot) of the interphase boundary. For Wulff plots without unstable interphase-boundary orientations, the two simulation methods are in excellent agreement with each other and confirm the general validity of the previously proposed theory. In addition, a crystallographic "locking" of the lamellae onto a facet plane is well reproduced in the simulations. When unstable orientations are present in the Wulff plot, it is expected that two distinct values of the tilt angle can appear for the same crystal orientation over a finite θ(R) range. This bistable behavior, which has been observed experimentally, is well reproduced by BI simulations but not by the PF model. Possible reasons for this discrepancy are discussed.

Scaling theory of two-phase dendritic growth in undercooled ternary melts

Two-phase dendrites are needlelike crystals with a eutectic internal structure growing during solidification of ternary alloys. We present a scaling theory of these objects based on Ivantsov's theory of dendritic growth and the Jackson-Hunt theory of eutectic growth. The additional introduction of the relationship ρ∼λ (ρ: dendrite tip radius; λ: eutectic interphase spacing) suggested by recent experimental results [S. Akamatsu et al., Phys. Rev. Lett. 104, 056101 (2010)] leads to a complete solution of theselection problem and to the scaling rule ρ∼λ -1/2 (v: dendrite tip growth rate).

Long-time dynamics of the directional solidification of rodlike eutectics

We report long-duration real-time observations of the dynamics of hexagonal (rodlike) directional-solidification patterns in bulk samples of a transparent eutectic alloy. A slight forward curvature of the isotherms induces a slow dilatation of the growth pattern at constant solidification rate and triggers the rod-splitting instability. At long times, the rod-splitting frequency exactly balances the dilatation driven by the curved isotherms. The growth pattern is then disordered and nonstationary but has a sharply selected mean spacing. Well-ordered growth patterns can be grown using time-dependent solidification rates.

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.

Experimental evidence for a zigzag bifurcation in bulk lamellar eutectic growth

We present real-time observations of the directional-solidification patterns of a transparent nonfaceted eutectic alloy (CBr4-C2Cl6) in bulk samples. The growth front of the two-phase solid is observed from the top through the liquid and the glass wall of the container with a long-distance microscope. We show that, in near-eutectic CBr4-C2Cl6 alloys, the upper stability limit of the stationary lamellar patterns is due to a zigzag bifurcation, which occurs at an interlamellar spacing of about 0.85 lambda(m), where lambda(m) is the minimum-undercooling spacing. The zigzag patterns undergo a lamella breakup instability leading to the creation of new lamellae at about 1.1 lambda(m). On the other hand, the lower stability limit of the stationary patterns is due to the same instability as in thin samples, namely, a lamella termination instability that occurs at about 0.7 lambda(m).

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.