Analysis of the high growth-rate transition in Al–Si eutectic solidification

The local solidification conditions and mechanisms associated with the flake-to-fiber growth mode transition in Al–Si eutectic alloys are investigated here using Bridgman-type gradient-zone directional solidification. Resulting microstructures are examined through quantitative image analysis of two-dimensional sections and observation of deep-etched sections, showing three-dimensional microstructural features. Several microstructural parameters were investigated in an attempt to quantify this transition, and it was found that the particle aspect ratio is effective in objectively identifying the onset and completion velocity of the flake-to-fiber transition, whereas traditional spacing parameters are not effective indicators of the transition. For a thermal gradient of 7–14 K/mm, the transition was found to occur in two stages, appearing over velocity regimes from 0.10 to 0.50 mm/s and from 0.50 to 0.95 mm/s. The initial stage is dominated by in-plane plate breakup and rod formation within the plane of the plate, whereas the second stage is characterized by the onset of out-of-plane silicon rod growth, leading to the formation of an irregular fibrous structure. The boundary between the two stages is marked by widespread fibrous growth and the disappearance of the remnant flake structure, indicating a transition in the structural feature that governs the relevant diffusion length, from inter-flake spacing to inter-rod spacing.