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The freckle formation and evolution in directionally solidified single-crystal specimens with different thicknesses and abruptly expanding rectangular cross-section were investigated at different withdrawal rates. The microstructure was studied by optical microscope (OP) and scanning electron microscope (SEM), and the crystallographic orientation in freckle areas was characterized by electron backscattered diffraction (EBSD). The experimental results showed that the freckle was the most severe in specimens with a thickness of 10 mm at the same withdrawal rate, and the freckle chain was observed to form below an abruptly expanding cross-section ended at the expanding step. It was found that freckles formed exclusively on the edges of casting facing the central sprue of the shell mould. Findings reveal that freckles tend to form at the highest position of the mushy zone, mainly due to the thermosolutal convection and the radial flow caused by feeding behavior in the mushy zone. The freckle formation is pronounced at a low withdrawal rate, and can further generate stray grains. • Freckle formation is more pronounced at a low withdrawal rate of 1 mm/min. • Freckles form exclusively on the edges facing the central sprue of the shell mould. • Radial flow and feeding behavior play a major role in freckle position. • Freckle grains can evolve into stray grains at a low withdrawal rate of 1 mm/min. [ABSTRACT FROM AUTHOR]

The microstructure of single crystal superalloy with and without tin layer on the surface of as-cast and heat-treatment state was investigated by optical microscope (OM) and scanning electron microscopy (SEM). The composition of different regions on the surface was tested by energy dispersive X-ray (EDS). The reaction intermetallic compound (IMC) formed in the heat treatment process was confirmed by X-ray diffraction (XRD). The orientations of different microstructure in samples as heat treatment state were determined by electron back-scattering diffraction (EBSD) method. The porosity location in the interdendritic region was observed by X-ray computed tomography (XCT). The experiment results showed that the remained Sn on the surface of the superalloy reacted with Ni, and then formed Ni 3 Sn 4 in the as-cast state. Sn enriched by diffusion along the porosity located in the interdendritic region and γ + γ′ (contain a little of Sn) eutectic and Ni 3 Sn 2 formed in single crystal superalloy during heat treatment, and the recalescence behaviors were found. Ni 3 Sn 2 nucleated independently in the cooled liquid at the front of (γ + γ′) (Sn) eutectic. The nucleation and growth mechanism of the eutectic and Ni 3 Sn 2 IMC during heat treatment was discussed in the present paper. [ABSTRACT FROM AUTHOR]