Dynamics of particle-assisted abnormal grain growth revealed through integrated three-dimensional microanalysis

Abstract Secondary-phase particles are routinely dispersed in metals and ceramics to prevent grain growth and take full advantage of the small grain size in the mechanical properties of polycrystals. Somewhat surprisingly, the preferential or abnormal growth of a few grains is observed in particle-containing systems at relatively high temperature, which will limit the lifetime of the material. The origins and mechanisms of particle-assisted abnormal grain growth are widely contested. Here, we employ integrated three-dimensional X-ray imaging to throw new light on the complex interactions between grain boundaries and particles in an Al–Cu alloy as a model system. We observe abnormal grain growth in the presence of a highly non-random distribution of particles. The incipient grain size is set by the local distribution of particles such that the larger grains come from particle-poor regions. Subsequently, grains with a size advantage may “run away” from the grain size distribution, in agreement with predictions from an analytical model that takes into account the competing capillary and particle pinning pressures.