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Abstract: Al–40% Cu hypereutectic alloy samples were successfully directionally solidified at a growth rate of 10μm/s in different sizes (4mm, 1.8mm, and 0.45mm thickness in transverse section). Using the serial sectioning technique, the three-dimensional (3D) microstructures of the primary intermetallic Al2Cu phase of the alloy can be observed with various growth patterns, L-shape, E-shape, and regular rectangular shape with respect to growth orientations of the (110) and (310) plane. The L-shape and regular rectangular shape of Al2Cu phase are bounded by {110} facets. When the sample size was reduced from 4mm to 0.45mm, the solidified microstructures changed from multi-layer dendrites to single-layer dendrite along the growth direction, and then the orientation texture was at the plane (310). The growth mechanism for the regular faceted intermetallic Al2Cu at different sample sizes was interpreted by the oriented attachment mechanism (OA). The experimental results showed that the directionally solidified Al–40% Cu alloy sample in a much smaller size can achieve a well-aligned morphology with a specific growth texture. [Copyright &y& Elsevier]

Abstract: Bridgman type directional solidification experiments were carried out in Nd14Fe79B7 alloy. Microstructure evolutions along with growth velocities were investigated. At low velocities from 1 to 200μm/s, the microstructures consisted of leading α-Fe dendrites and peritectic Nd2Fe14B phase in the interdendritic region. At medium velocities of 425 and 500μm/s, an incomplete banded structure formed, containing circles of α-Fe/Nd2Fe14B–Nd2Fe14B dendrites. At high velocities of 1, 3 and 5mm/s, a transition from γ-Fe dendrites to Nd2Fe14B dendrites occurred. Phase selection phenomena were theoretically studied using the extremum criterion which assumes growth-controlled phase selection. The theoretical results are in agreement with experimental results at low velocities of 1–200μm/s and high velocities of 3 and 5mm/s. The incomplete dendritic bands at 425 and 500μm/s were explained by nucleation of Nd2Fe14B phase at the γ-Fe dendritic interface, and growth competition between γ-Fe and the nucleated Nd2Fe14B phase. Phase transition from γ-Fe to Nd2Fe14B at 1mm/s was interpreted by abundant nucleation and quick growth of Nd2Fe14B phase at the γ-Fe dendritic interface. [Copyright &y& Elsevier]