Microstructure development in the directionally solidified Al–4.0 wt% Cu alloy system

The effect of convection on microstructure formation is examined experimentally and theoretically for the vertically upwards-directional solidification of Al–4.0 wt% Cu alloys. In this alloy system, the rejected solute is heavier than the solvent so that fluid flow occurs due to the presence of radial gradients in temperature and composition. A numerical model is presented which shows that convection effects cause the composition to vary along the interface such that the composition increases from the center to the periphery of the sample. This composition variation causes the macroscopic interface to become convex, and give rise to a systematic variation in microstructure along the interface. Critical experiments have been carried out to examine planar to cellular (and cellular to dendritic) transition in a given sample due to the increase in concentration along the interface, and the experimental results are analyzed through the measurements of interface composition and thermal gradient. In addition, the variation in local primary spacing with interface composition is also characterized and compared with the results of the numerical model. It is shown that microstructure transitions and microstructural scales can be correlated quantitatively with the theoretical results based on interface composition and on temperature and solute gradients at the interface.